How to make female cosplay armor?

Materials and Tools

• EVA Foam: Available in various thicknesses, EVA foam is flexible, easy to shape, and comfortable to wear.
• Craft Knife/X-Acto Knife: For precise cutting.
• Heat Gun: To shape the foam.
• Cutting Mat: To protect your work surface.
• Contact Cement: For strong, flexible bonds.
• Primer and Paints: To finish and decorate your armor.
• Plastic Wrap and Duct Tape: For creating patterns.
• Markers and Rulers: For measuring and marking.
• Elastic Strips and Velcro: For attaching and wearing the armor.

Step-by-Step Guide

1. Creating Patterns

Using Plastic Wrap and Duct Tape

1. Wrap Yourself: Wear the undergarments you plan to use with your cosplay. Wrap your torso in plastic wrap, followed by a layer of duct tape. This will help create a mold of your body.
2. Draw the Design: Use a marker to draw the design of your armor directly on the duct tape. Include registration marks and seam lines for easier assembly.
3. Cut Out the Pattern: Carefully cut the duct tape mold off your body. Flatten it out and trace it onto paper to create a clean pattern.

Using Pre-made Patterns

2. Cutting and Shaping the Foam

1. Trace the Patterns: Transfer your paper patterns onto EVA foam using a marker.
2. Cut the Foam: Use a craft knife or X-Acto knife to cut out the foam pieces. Make sure to cut at a 90-degree angle for clean edges.
3. Heat and Shape: Use a heat gun to soften the foam. Shape it to fit your body by bending and molding it while it’s warm. Let it cool to set the shape.

3. Assembling the Armor

1. Glue the Pieces: Use contact cement to glue the foam pieces together. Apply the cement to both surfaces, let it dry for a few minutes, and then press the pieces together.
2. Reinforce Seams: For added strength, reinforce seams with additional strips of foam or fabric on the inside.

4. Detailing

1. Add Details: Cut additional foam pieces for raised details, such as edges, patterns, or emblems. Attach these with contact cement.
2. Smooth Edges: Use a Dremel tool or sandpaper to smooth and round the edges of your armor.

5. Priming and Painting

1. Prime the Foam: Apply a primer like Gesso or Plasti Dip to seal the foam and prepare it for painting. This helps the paint adhere better and provides a smoother finish.
2. Base Coat: Apply a base coat of paint. For a metallic look, use silver or gold spray paint.
3. Detail Painting: Use acrylic paints for detailed work. Dry brushing techniques can add weathering effects for a more realistic look.

6. Straps and Attachments

1. Elastic Strips and Velcro: Attach elastic strips or Velcro to the armor pieces to secure them to your body. Ensure they are comfortable and allow for movement.
2. Test Fit: Wear the armor and make any necessary adjustments to the fit and comfort.

7. Final Touches

1. Weathering: Add weathering effects with black or brown paint to give your armor a battle-worn look.
2. Seal the Paint: Use a clear sealant to protect the paint and give your armor a finished look.

Additional Resources

• Kinpatsu Cosplay: Offers detailed tutorials and pattern sets for both masculine and feminine armor.
• Skillshare: Provides classes on making EVA foam armor, including pattern making, assembly, and painting techniques.
• Instructables: Features step-by-step guides on creating cosplay armor from EVA foam.

Tips for Success

• Start Simple: If you’re new to cosplay armor, start with simpler designs and gradually take on more complex projects.
• Take Your Time: Rushing can lead to mistakes. Take your time with each step to ensure the best results.
• Practice Safety: Always wear a mask when cutting or sanding foam to avoid inhaling dust. Use gloves when working with contact cement.