How to make fake armor for cosplay?

How to Make Fake Armor for Cosplay

Materials and Tools

Materials

• EVA Foam: This is a flexible, soft foam rubber commonly used in sports equipment. It’s easy to work with, conforms to the body, and is comfortable to wear.
• Cardboard: An inexpensive and widely available material, cardboard can be sturdy when reinforced but is less comfortable and harder to mold.
• Thermoplastics (e.g., Worbla): Ideal for detailed pieces, thermoplastics can be shaped using heat and are popular for creating armor and props.
• Fabric: Used for capes, banners, and other costume pieces, fabric is easily found and versatile.

Tools

• Scissors and Craft Knife: Essential for cutting materials accurately.
• Heat Gun: Used for shaping thermoplastics and EVA foam.
• Glue Gun: For assembling pieces together.
• Sanding Tools: To smooth edges and surfaces.
• Paints and Brushes: For adding color and details to your armor.
• Measuring Tape: To ensure accurate measurements.

Step-by-Step Guide

Step 1: Design and Pattern Creation

1. Choose a Character: Select a character whose armor you want to replicate. Gather reference images from different angles to understand the design.
2. Sketch Your Armor: Draw a rough sketch of the armor, highlighting different elements and how they overlap.
3. Create a Template: Use poster board to create a mockup of your armor. Wrap it around your torso and mark key points like the neckline, armholes, and edges.
4. Transfer to Pattern Paper: Once satisfied with the mockup, transfer the shapes to pattern paper using an awl or pounce wheel.

Step 2: Cutting and Shaping

1. Cut EVA Foam: Lay out your pattern pieces on EVA foam and cut them out using a sharp craft knife. Ensure smooth cuts by using a fresh blade.
2. Shape with Heat: Use a heat gun to shape the foam pieces. For thermoplastics like Worbla, heat the material until it becomes pliable, then mold it to the desired shape.
3. Assemble Pieces: Temporarily assemble the pieces without glue to check the fit. Make any necessary adjustments before final assembly.

Step 3: Assembly

1. Glue Pieces Together: Use a hot glue gun to attach the pieces. For added strength, consider reinforcing joints with additional strips of foam or thermoplastic.
2. Add Details: Cut additional strips of EVA foam to add details like ridges and borders. Glue these onto the main armor pieces.
3. Straps and Fasteners: Attach elastic strips or Velcro to secure the armor pieces to your body. Ensure that the fasteners are comfortable and allow for easy movement.

Step 4: Painting and Weathering

1. Prime the Surface: Apply a primer to the foam or thermoplastic to prepare it for painting. This helps the paint adhere better and provides a smoother finish.
2. Base Coat: Apply a base coat of paint using acrylics. Metallic paints are great for replicating the look of metal armor.
3. Weathering: Use techniques like dry-brushing to add weathering effects. Dip a brush in black paint, wipe most of it off, and lightly brush the edges and corners to create a worn look.
4. Seal the Paint: Once the paint is dry, seal it with a clear coat to protect the finish and add durability.

Additional Tips and Tricks

Working with EVA Foam

• Heat Shaping: Use a heat gun to make the foam more flexible and easier to shape. Be careful not to overheat, as this can cause the foam to warp or burn.
• Detailing: Use embossing tools to add intricate details to the foam. This can enhance the overall look of your armor.

Using Thermoplastics

• Shaping: Thermoplastics like Worbla can be heated and shaped multiple times. This allows for adjustments and fine-tuning of your armor pieces.
• Layering: Layering thin pieces of thermoplastic can create more complex designs and add depth to your armor.

Painting Techniques

• Layering Paint: Apply paint in thin layers to avoid drips and achieve a smooth finish. Allow each layer to dry before applying the next.
• Highlighting and Shadows: Use lighter colors to highlight raised areas and darker colors to add shadows. This creates a more dynamic and realistic appearance.

Resources and Inspiration

• CrazeCosplay.com: Offers a comprehensive guide on creating cosplay armor, including tips on working with EVA foam and thermoplastics.
• Skillshare Blog: Provides tutorials on making EVA foam armor and other cosplay elements.
• Excel Blades Blog: Features step-by-step guides for creating foam armor, including pattern creation and painting techniques.
• YouTube Tutorials: Channels like Cosplay Apprentice offer video tutorials on making foam armor, providing visual guidance and tips.

Conclusion