How to make armor for cosplay?

How to Make Armor for Cosplay

Materials and Tools

Materials

1. EVA Foam: This is the most popular material for cosplay armor due to its flexibility, ease of use, and comfort. EVA foam comes in various thicknesses, typically ranging from 2mm to 10mm. Thicker foam is used for structural pieces, while thinner foam is ideal for details.
2. Worbla: A thermoplastic material that becomes moldable when heated. It's excellent for adding details and creating more rigid armor pieces.
3. Foam Clay: Used for sculpting intricate details that can be added to your armor.
4. Adhesives: Contact cement (e.g., Barge cement) is preferred for its strong bond, but hot glue and super glue can also be used for smaller details.
5. Primers and Sealants: Plastidip is commonly used to seal foam before painting. Flexible primers and sealants help ensure the paint adheres well and doesn't crack.
6. Paints: Acrylic paints are widely used for their versatility and availability. Metallic paints can give your armor a realistic metal look.
7. Elastic Straps and Velcro: Used for attaching armor pieces to your body.

Tools

1. Cutting Tools: Scissors, x-acto knives, and box cutters are essential for cutting foam and other materials. Keep replacement blades handy as they will dull quickly.
2. Heat Gun: Used to shape EVA foam and activate Worbla.
3. Dremel Tool: Essential for sanding and detailing foam edges.
4. Measuring Tape: For accurate measurements of your body and materials.
5. Markers: Black and silver sharpies for marking patterns and details.
6. Plastic Wrap and Duct Tape: Useful for creating body patterns.

Step-by-Step Guide

Step 1: Design and Planning

• Reference Images: Collect images of the character from different angles to understand the armor's structure and details.
• Patterns: You can create your own patterns using plastic wrap and duct tape. Wrap the plastic around the body part you are designing for, cover it with duct tape, and draw the armor pieces directly onto the tape. Cut out the pieces to create your pattern.

Step 2: Cutting and Shaping

1. Transfer Patterns: Trace your patterns onto the EVA foam using a marker. Ensure you label each piece to avoid confusion during assembly.
2. Cutting: Use a sharp x-acto knife or box cutter to cut out the foam pieces. For clean edges, make multiple shallow cuts rather than trying to cut through the foam in one go.
3. Shaping: Use a heat gun to heat the foam pieces, making them pliable. Shape the foam by hand or over a form (e.g., a rounded object for curved pieces). Hold the shape until the foam cools and hardens.

Step 3: Assembly

1. Gluing: Apply contact cement to the edges of the foam pieces you want to join. Let the adhesive dry until it becomes tacky, then press the pieces together. For smaller details, you can use hot glue or super glue.
2. Detailing: Add details using thinner foam or foam clay. For intricate designs, Worbla can be heated and molded into shape, then adhered to the foam.
3. Sanding: Use a Dremel tool to smooth out edges and seams. This step is crucial for a professional finish.

Step 4: Sealing and Priming

1. Sealing: Apply a few coats of Plastidip to seal the foam. This creates a smooth surface for painting and helps prevent the foam from absorbing paint.
2. Priming: Use a flexible primer suitable for foam and plastics. Apply multiple thin coats, allowing each coat to dry completely before applying the next.

Step 5: Painting

1. Base Coat: Apply a base coat of paint using acrylics. For metallic armor, start with a dark base coat.
2. Detailing: Add highlights, shadows, and weathering effects to give your armor a realistic look. Dry brushing and washes are effective techniques for adding depth and texture.
3. Sealing: Once the paint is dry, apply a clear sealant to protect the paint and add durability. Matte sealants are generally preferred for a realistic finish, but gloss can be used for specific effects.

Step 6: Strapping and Fitting

1. Straps and Buckles: Attach elastic straps and buckles to the armor pieces to secure them to your body. Ensure the straps are adjustable for a comfortable fit.
2. Velcro: Use Velcro for pieces that need to be easily removable or adjustable.
3. Testing Fit: Wear the armor and test for comfort and mobility. Make any necessary adjustments to the strapping or padding to ensure a good fit.

Advanced Techniques

Weathering

• Dry Brushing: Lightly brush metallic paint over raised areas to simulate worn edges.
• Washes: Apply a diluted paint wash to recessed areas to add depth and grime.
• Battle Damage: Use a Dremel tool to create scratches, dents, and other damage effects.

Electronics

Resources and Inspiration

CrazeCosplay.com

Rank No.1

Tips and Tricks

1. Practice Makes Perfect: If you're new to cosplay armor making, start with small projects to build your skills before tackling more complex designs.
2. Stay Organized: Keep your workspace tidy and label all your pieces to avoid confusion during assembly.
3. Safety First: Always work in a well-ventilated area when using adhesives and paints. Wear a mask and gloves to protect yourself from fumes and chemicals.
4. Learn from Others: Join cosplay communities online, such as Reddit's r/cosplayprops, to share tips, ask for advice, and learn from experienced cosplayers.

Conclusion