How thick should EVA foam be for cosplay - Cosplay Quick Tip Clip | Cosplay Apprentice

Cosplaying with EVA Foam is fun easy and inexpensive and if you are using the right EVA foam you can produce super high quality results even as a beginner. But, when starting off you may wonder what is the right kind of EVA foam to use and how thick should it be for the uses that you need. In this video I will give you tips on the best foam to use and the right thicknesses to get based on what you are making.
Foam Floor Mats and Traditional Cosplay Foam Armor
Base thickness for armor - 6mm-10mm
Details - 2mm, 4mm, 6mm and up if costume dictates
W+F (What The Foam)
Base Thickness for Armor - 4mm or 6mm if the costume has a thicker look.
Details - 2mm, 4mm, 6mm
Props
Base 10mm and up
Details all thicknesses depending on look.
Please enjoy and let me know what Cosplay Questions you might have and I will answer them in a video on this channel! Cosplay On, My Friend!
Here are links to the different foams I would recommend, if you buy some please use these affiliate links, it gives me a kickback at no cost to you that will help me continue to create these videos. Thanks! Cosplay On, My Friend!
What The Foam (W+F) - amzn.to/39HHeq2
Thicker Normal Foam - amzn.to/2uf408x
Support me on Patreon: / cosplayapprentice
Follow me on Instagram: / cosplay_apprentice

[@ronentat]

Eva. Your channel is the one that gives me the information I wanted to start building and realising a 35 year old dream.

[@CosplayApprentice]

Wow!!!! That makes me so happy to hear!!!! :) thank you for your comment! :)

[@Basickiwi]

This was super helpful! Im looking into making mandalorian armour. Was not sure on what thickness would be the best, but you explained everything perfectly! EVA

[@CosplayApprentice]

Yay!!! I'm so glad it was helpful!!! :)

[@ashllynn1013]

EVA. Thank you so much, I’ve been asking my family for advice for like a month

[@CosplayApprentice]

So glad I could help!! :)

[@killashandrad]

Finally bought your template for Hiccup Chest Plate, and made it using 10mm foam, woah its soo tick :D I ended up doing only 2 "layers" of armors pieces instead of 3 and only 1 collar piece ! Still looks amazing and was a good base for a a bulkier armor ! Thanks for the informative videos!

[@CosplayApprentice]

Yay! I'm glad it turned out for you! :) Thank you so much for your support and for watching. If you post the chestplate on Instagram or anything please tag me in it, is love to see it! :) @cosplay_apprentice Thank you!

[@killashandrad]

@@CosplayApprentice Will do ! An idea I have for a potential video is how to create patterns, what I mean here is I get the whole "wrap yourself in paper and draw lines and registration marks" but I dont understand where and how to make the seems to make the shape flat! Does that make sense?! I always end up with way too many pieces that are making unecessary cuts or not enough and the shape isnt completely flat. I hope Im not the only one who struggles with this ! Just an idea :)

[@CosplayApprentice]

Thank you so much for that idea! You are definitely not the only one with that problem and I will add that to my list that will be coming out next month! :)

[@CosplayApprentice]

Also thank you for the detailed explanation, it helps a ton to get more in depth description of the issue so I can better answer the question. :)

[@Nonskiller]

I like 4 MM Foam. Once you go 4... you never go back to 6. But.. 6 mm gives you more options; not just in thickness but if you got special tools you can abuse the 6mm foam to have more distinct looks to it. 4mm is best though. .. and 2mm.. umm.. ye.

[@CosplayApprentice]

Definitely! :) I love 4mm! True, there are definitely some beneficial things to 6mm :) 4mm is my go to and 2mm WTF opens so many possibilities not available with other 2mms :)

[@beckymurphy4714]

I snagged a garbage bag full of foam play mats at our local Goodwill - the kind that interlock, and have letters or numbers that can be popped out. Fortunately there were several solid pieces in there, and I used some to build the structure of my dragon helm. I have to experiment with one to see if the textured side can be removed so I can use them for making weapons without having to glue something to the back to hide the texture. Yoga mats work, too, for armor builds - I used one to make the horns on the helm (stuffed with plastic bags). Just a couple of inexpensive alternatives for folks who are just getting started, or, like me, are cosplaying on a budget.

[@davidcamacho8935]

I have had success sanding off the texture in the past, just takes some time

[@rockurox]

THANK YOU SO MUCH FOR THE DURABILITY TESTS!!!

[@brooklynnwilmoth4907]

This is really helpful! I tried making something out of 5mm but it didn't work so I had to scrap it. So imma try it with something thicker. But I need to know what primer you used to make the Hiccup armor hard, was it plasti-dip?

[@glasshalffull2930]

Everything I’ve read/seen recommends Plastidip.

[@lorenemateo3804]

Thank you very helpful. I subscribed. Looking forward to learning and supporting your channel

[@CosplayApprentice]

Yay! Glad it was helpful! :) Thank you so much!!!

[@godofgods300]

this was amazing advice clearly you are an expert! thank you tons!

[@CosplayApprentice]

Thank you! I'm glad I could help! :)

[@sheryanimefan7753]

eva, thanks for the tips!

[@ati1010]

EVA. Thank you!

[@lindsayregalado5852]

What thickness would you suggest for football pads for a 10 yr old's Halloween costume, that gives the looks of the big shoulders, without too much bulk, so he can still move easily, for when it is worn at school?

[@magicalmecosplay]

THIS IS PERFECT...Redoing my armor on my Dora Milaje will invest in that 2mm and 4mm "What The Foam" and see how that goes. ok so next issue I am having is attaching the Armor if you can see how I rigged it to stay on you would be shocked lol, safety pins and plastic straps. Can you show the best way to attach armor especially like the one you used in this example (sitting on the shoulder) My Cersie I used velcro and that seems to work but I have a battle version of Cheetara I am doing and cant find a way to attach it to my shoulder as it is on bare skin.

[@beckymurphy4714]

For Cheetara I'd recommend doing a harness, where the pauldron (shoulder armor) has a strap crossing diagonally across the chest and under the opposite arm. Then a strap towards the bottom that goes around your upper arm. Similar to this: images-na.ssl-images-amazon.com/images/I/9162PMkpikL._SL1500_.jpg

[@CosplayApprentice]

Yay! Let me know if you have questions as you work with it! :) Great questions on armor attachments! I will make sure to add that to my list :)

[@dhayjanirelouisanneau4490]

Eva, but what is the density? Like lox or high I can't find the info😭

[@sophiaroth1930]

Density is how dense the material is, so a low density foam is going to be floppier and a high density one will be sturdier, more like a board but still bendable with heat. (this is just the information I have gathered, I don't have much experience handling foam)

[@L0v3dNL0st]

My main issue is I live in Phoenix so it doesn't stand up to 110⁰ heat like at all. It'll lose its shape and even the contact cement stops holding if you're outside waiting to get into the con.

[@catalystcomet]

What contact cement did you use?

[@L0v3dNL0st]

@@catalystcomet I've used weldwood and Elmer's.

[@newworldordernwo2368]

Can i use eva Craft foam for sword And i can i glue 2mm to a 8mm foam sheet

[@nickolasbarnes4430]

Some day I wont have to buy floor mats from Harbor Freight. Im not really poor but I think I suck to much to buy nice things.

[@CosplayApprentice]

I'll tell you a secret, it is most likely not your skills, but the poor quality foam that is holding you back. I have seen many people that have decent talent get frustrated and produce poor results using floor mat foam and then when they switch to a higher quality foam many of their perceived lack of skills disappeared and they found it easier to make good looking results. :)

[@aidanschutte7498]

EVA. Thanks a bunch!!

[@CosplayApprentice]

Thanks for watching!!! :)

[@americanhwyflower]

Hi. I am making the gladiator skirt from marvin martian and also his helmet. I want to use the same foam for both. What thickness should I get that is stiff enough to make the skirt stand up but also pliable enough to shape the helmet? I have never made anything before

[@CosplayApprentice]

If you are wanting to use the same thickness for both I would go with 4mm What The Foam. That's going to be the best way to go to get the strength you need for the helmet but not he too thick for your skirt. :)

[@HoshiHikari]

Can I use contact cement and layer foam together to thicken 2mm foam to use as 4/6/10mm foam? Or will it lose its flexibility?

[@CosplayApprentice]

You can probably Layer them together, it will just be harder to cut and heat shape without the heat causing the contact cement to release.

[@HauntedCarnie]

if you're wanting to add foam to a rubber mask to make it more comfortable to wear, what thickness would you go with? I'm wanting to add some padding to the forehead area

[@SOULJAHX6]

When printing a pattern, how do you account for the foam thickness?

[@happyfoxtail2062]

I'm not sure which would be the best size MM for chest armour?? I'm doing a Halo ODST set and not entirely sure which thickness is best for shape/hold and durability? 🤔

[@CosplayApprentice]

If it is out of What The Foam then 4 mm works great, other wise I would at least go with 6mm or higher if you are using other Eva foams :)

[@kayleighbaileybumm]

Biggest challenge for me has been making templates alone!

[@costcocookies273]

Any tips for making masks? (Examples: Midoriya’s Deku mask, Shinsou’s mask, plague mask, etc.) and is it necessary to use a heat gun for shaping foam? Or can you use a hair dryer?

[@CosplayApprentice]

My spiderman faceshell video can help give you some ideas and also my patterning playlist series. Hope that helps :)

[@costcocookies273]

@@CosplayApprentice thanks!

[@CosplayApprentice]

Sure thing! Happy to help!!

[@spoon1245]

EVA! Planning on Halo cosplay armor, you said to use 4-6mm for armor and such. However, W+F only has 4mm, what should I do?

[@CosplayApprentice]

With W+F 4mm is a great base for any armor pieces, 2mm and 6mm would be more for details or if you need extra thickness somewhere. We are sold out of our 6mm right now but we do have variety packs that come with 2mm,4mm,and 6mm (3of each) if you need se 6mm. But if I was build a halo armor set I would use the 4mm as my base for any armor pieces. Also, he are having a sale on W+F right now on Amazon it is 20% off:) let me know if you have any other questions, I am happy to help! :)

[@aknick5]

Hello, my daughter is in 4H and is going to be competing in a costume contest with our white golden retriever. We have the head figured out but we wanted to use a grey EVA that wasn't to heavy to make the top and sides of the sharks body and fins. Then we would need it to support some type of strap/velcro to secure the piece on the dogs back and around their chest and hips.. What type of foam would be best and lightweight? Thank you! Dog from neck to tail is 38" L and width needed is 24" and would need it in grey. Thank you!

[@CosplayApprentice]

SKS props foam is naturally a light grey color and he has a couple different thicknesses of EVA foam that he offers. I think a 4or5mm would be nice. You can get his foam on Blicks I think. :)

[@aknick5]

@@CosplayApprentice , thank you so much for responding so quickly. Unfortunately, the size and thickness I need is out of stock and finding grey in a width I need seems to be hard to find. If I purchase the white EVA foam I will need to paint it grey so If I seal it with the grey plasti dip would I still need to actually paint it with a grey paint afterwards ? Again this is for a shark dog costume that will be worn once, maybe twice. Thank you!!!!

[@VincentD20]

How thick would you recommend for "The Batman" 2021 suit armour? Including shoulders, torso, abdominal, chest (where thale bat logo is) and all, as well as the wrist gauntlets?

[@CosplayApprentice]

4mm What The Foam would work pretty well for most of the suit!! :)

[@harlins70]

Can you use 5mm Eva for a pumpkin head costume? Ty

[@CosplayApprentice]

You should be able to, and it will probably make the curved seams easier. For your pumpkin sections I would probably advise cutting the sections out with an outward bevel cut on one side and an inward bevel cut on the other. This will give you more surface area to glue to and make those seams happen more naturally :)

[@thickmclargehuge4448]

eva, very helpful

[@CosplayApprentice]

Thanks!!

[@colboy1fish]

Unfortunatly I didn't get an answer. I want to build a Warhammer space marine armor but I can't decide between 7 or 10mm for the armor. Its going to be huge (I made stilts to make me 210cm or about 7") but I am not sure how thick I need to buy it, since you will be able to tell the thickness in places.

[@hilaryglad827]

Thank you for sharing this information! My son wants to be a cello for Halloween. I've been trying to focus out how to make it happen and came across EVA foam. Since I've never used it before I'm trying to sort through information to coiffure out the best route to go. He will need to be able to sit when he's in school so I'm trying to balance it holding its shape and being flexible enough to sit. Do you have any recommendations? If all else fails he may just have to take it off when he has to sit down. If that's the case I'll need it easy for an 8 year old to take on and of on his own.

[@aBlueMoon91]

Hey ,I'm making my first armor ,so I'm a complete beginner with foam armor . Would you say then, For a breast plate 4-5 mm is best ?

[@CosplayApprentice]

Yes, I would recommend 4,5,or 6mm If you use our foam "WTF (What The Foam)" 4mm would be the way to go as it is much more durable and has a great shape hold at that thickness. Otherwise if you are going to use something from TNT Cosplay Supply or SKS Props HD Foam then I would go with the 6mm foam. :) Hopefully that helps :). Also I have a video making wonder woman's breastplate that might be helpful to see the process for making a pattern for the breastplate. I used a thicker foam in that that was about a 12mm and but I wish I had used thinner foam. :)

[@gasman9845]

what is the name of the orange foam that you use for straps. hearings not the best thx

[@CosplayApprentice]

It is called What The Foam! :). There should be a link in the description. :)

[@starrchild2010]

@cosplay apprentice I want to do Mademoiselle from My hero academia. Im conflicted as to what thickness of eva foam to use. It needs to be thick enough to do the cut outs (at least thats what they look like to me) in the front by her mouth. Any help would be greatly appreciated. Thank you, Kelli

[@ChaozXIII]

you have to consider density too now that harder and stronger eva foam are available. especially for shoes

[@catspyjamass]

7:28 how did you get the soft 6mm EVA foam to become so rigid to form the shoulder armour? Thanks!

[@CosplayApprentice]

That 6mm foam is our What The Foam (WtF) it is stronger and stiffer than other Eva foams you can find :)

[@catspyjamass]

@@CosplayApprentice I don't understand how it transitions from super flexible to rock hard? Do you need to heat treat it?

[@CosplayApprentice]

When you heat it up it becomes malleable and flexible and once it cools it holds its shape :)

[@monsterman7261]

I'm trying to find out what foam would be best im trying to make master chief armor from halo infinite

[@CosplayApprentice]

My response may seem biased but for anything armor, I think our 4mm What The Foam is the best way to go, it holds it's shape really really well but is still thin so it is easy to pass as more realistic armor. Plus it's more durable than other foams and it cuts and sands super clean! :). I'm not just recommending it because it's my product, but because I think it is the right foam for most any foam armor project! :)

[@OLDSCHOOL6239]

I'm new to the whole hobby and here to learn. Unfortunately I think I've just made my first mistake. I not seeing to many people mention 3mm and 5mm High Density. Is one of these good enough to make a helmet? Or should I just break down and go purchase some 10mm Foam? Can Someone please advise me on this, Thanks a bunch.

[@CosplayApprentice]

A High Density 5mm foam will work to make a helmet, it might not be a super rigid helmet but I have made a few with 5mm before. Our What The Foam 4mm is excellent for helmets though and even though it is only 4mm thick it will hold it's shape super well and be a pretty rigid helmet. :)

[@OLDSCHOOL6239]

@@CosplayApprentice I went ahead and purchased some 10mm "WHITE" foam since making this comment. I'm going to go with making an Aliens Pulse rifle as my first project. Thank you so much for the response. I appreciate it.

[@CosplayApprentice]

Awesome!! Sounds great! Can't wait to hear how it goes! :). If you post online please tag me so I can see how it turns out! :)

[@iamthelambsauce9011]

EVA, sorry I know this video was made a year ago but I have a question if its possible to answer I am working on a masterchief mark6 armor and im still not sure on the thickness i should use😅

[@CosplayApprentice]

No problem at all, I try to respond to comments and questions on all my videos regardless of how old they are. :). If you are able to get our "What The Foam" I would recommend using 4mm, it will be perfect for master chief armor because it is thin but will hold it's shape really well. Otherwise, if you have to go with other foams, I would recommend trying to get a high density one that is smooth on both sides, I would try and make a 6mm high density foam work if you can to keep it thinner otherwise you might need to go with a 10mm. :) Hope that was helpful, feel free to ask any follow up questions you might have :)

[@iamthelambsauce9011]

@@CosplayApprentice oh thankyou so much :) do you think normal 4mm EVA foam works as well?

[@TheSharkInYourWater]

I still didn't found my answer XD if I wanted to do face mask, like one that tooru mutsuki had I would use 2mm that's for sure but do I need heat gun to heat this one? Also I want to use it as an alternative to a material to make it hold shape better

[@sunnydoom2726]

I have tried heating foam with a hair dryer and over a stove burner and neither work as well as a heat gun. Got mine pretty cheap at Harbor Freight. You don't need a fancy one. Thinner foam (like 2mm) *might* be ok but the heat gun will cause less frustration and also helps seal the foam before prime and paint.

[@CosplayApprentice]

So true, a great gun is the way to go. :)

[@ninetailorochimaru]

I commissioned a fox kabuki face mask, and it has a lot of bells and whistles and as a result is rather heavy. The padding foam used I'm told was car soundproof foam? But as a result it has way too much give, and gravity begins to lossen the straps and hurt my head as there is not enough support. Would you recommend Eva foam as a forehead padding, or would u recommend a cheaper, craft store foam? And if u do recommend something, let me know thickness as well please. I'm just looking for something small, so I'd rather not have to buy a whole roll for it. Thanks for your time and I hope you have a great day =) Stay Awes9me

[@CosplayApprentice]

EVA foam can work well as padding in a helmet or mask. I would use a softer squishy one. You can get foam floor mat tiles from harbor freight for like $8 and those would work they are around a 1/2" thick. Or if you want really squishy upholstery type foam that it thicker and even more padded you can pick up a 2'x2' square of it at home Depot or Lowes for a few bucks. :)

[@ashtonmalla3645]

Wahhh im not sure where to find the eva foam in the philippines 😭, is EVA foam expensive for a roll?

[@shannonv3683]

I made my 1st helmet (1st anything with EVA foam). My son wants a Marvin the Martian helmet for Halloween. I used 6mn foam. I think the shape turned out ok, but it's wobbly. Any tips for what I can do to make it more rigid? Maybe line the inside with something?? Thanks!

[@CosplayApprentice]

Sounds awesome!! Congrats on making your first foam piece!! I'm super excited for you! :) Where did you get the 6mm foam from? (ex. Is it floor mat foam, or craft foam,etc.) Have you already plastidipped and painted the helmet or is it still raw foam?

[@shannonv3683]

@@CosplayApprentice I bought my EVA foam from Michael's. It's the Art Minds brand. I have not sealed it yet.

[@CosplayApprentice]

Ok, nice. So a couple things you can do. A lot of times just plastidipping and painting will help it stiffen up a bit. But if you are really concerned about you could definitely run some strips of foam on the inside to help it hold it's shape better. You could also add whatever kind of padding you might want on the inside of the helmet to help it fit snug and comfy on the head and that might help give it some more rigidity as well. Hope that helps :) please feel free to follow up with any additional questions :) I am happy to help!

[@shannonv3683]

@@CosplayApprentice thanks for the tips! That helped. I also added a hollowed out styrofoam half round to the inside & added some soft padding pieces for wearing. That helped stiffen it up to.

[@gasman9845]

sorry found it in description.

[@CosplayApprentice]

No worries :) I'm glad you found it! :) It's incredible stuff! Let me know if you have any questions about it, I'm happy to help. :)

[@johnconstantine5548]

So is 8mm good for an armor or is it too bulky cause I already bought it🤣🤣

[@CosplayApprentice]

Haha, if you already have it 8mm can work for armor just fine, that's what I made the Wonder Woman Breastplate with, you may just have to hide it's thickness by sanding down the visible edges a bit. If you checkout my video on my channel for the Wonder woman Breastplate you can see how it turned out. :)

[@joanne2984]

can someone provide me with a link to the thick 1.25-inch foam? Can't seem to find a link.

[@ms.pirate]

I wanna buy some of your foam, but its on Amazon, do you have an etsy or an official website?

[@CosplayApprentice]

No worries, we have our own website and we do sell our foam there as well. :). cosplayapprentice.zohocommerce.com/products/what-the-foam-factory-seconds/1647676000004544001

[@ms.pirate]

@@CosplayApprentice thanks!

[@hosmersgoldenretrievers]

EVA!

[@henwicksmenlundbergerkjekk5000]

Im actually here for putting foam in my keyboard

[@stewartpajaron9210]

Eva

[@spider-ty7420]

My greatest challenge is seam filling.

[@davidcamacho8935]

EVA

[@Boyscout533]

EVA boi

[@CosplayApprentice]

That's what's up! Thanks!! :)

[@obijohn1]

eva

[@CosplayApprentice]

Perfect!!

[@kz_da_kobbla]

I want to use it to make sneaker soles?

[@kathydenos3676]

Eva...

[@erinkristiansen7623]

Eva

[@CosplayApprentice]

Perfect!!!

[@meichen6932]

eva

[@CosplayApprentice]

Yay!!

[@tobias3170]

EVA

[@Hannah-pn1bx]

EVA

[@devirweems]

Eva

[@jacobgraybeal39]

EVA

[@kathydick3152]

Eva

[@TheBuddys1234]

EVA

[@agastyadagoat9526]

Eva

[@cagirlmja]

Eva

[@Deadacount601]

EVA

[@CosplayApprentice]

Yay!!!

[@jacobteel7858]

EVA

[@ringo40]

EVA

[@davidwilson8947]

EVA

[@bradwhittemore5900]

EVA

[@karenshiver6524]

EVA