How to Make a Foam Dome and other pattern making techniques

I'm the Evil Ted who makes props and costumes. I’ve worked on Star Trek Into Darkness, Walking Dead, Fifth Element and Guyver, among lots of others. I've made pretty much everything out of every material, but foam is my favorite.
I'm here to share my skills and shortcuts, and help you learn how to make foam costumes and props, too.
To see more, check out my site: eviltedsmith.com
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[@CarloRufinoSabusap]

I've also used a plastic beach ball from the dollar store and cut it alone the curvature lines. Makes a great pattern as the curves are already in the design!

[@EvilTedSmith]

+Carlo-Rufino Sabusap Ah, good ideal.

[@rabbit0664]

hy didn't I think of that? I got mine online.

[@gidgetsmart7186]

That's what I was thinking of doing. Thanks for letting me know it works!

[@corncobjohnsonreal]

if you need a dome to make a dome, where did the first dome come from?

[@timothyjones8921]

A-dome and Eve.

[@roryyeatman999]

Timothy Jones you mean Eva

[@HYBECTIVE]

Corncob Johnson real make it out of cardboard

[@GuardianAssassin]

I often wondered who invented the hammer that helped make a better hammer...

[@aaimaadil3242]

was wondering te same thing

[@thenerdofalltrades8190]

This is what makes the internet so great. An expert like you can share knowledge with the world for free. Thank you!

[@EvilTedSmith]

My pleasure!

[@pamelashelley6547]

Ted, you read my mind! How did you know I needed a dome tutorial? It all seems so obvious and simple when you explain it! Oodles of thanks!

[@scottharper3912]

A very nice tutorial! I will be using the dome idea to do shoulder armor for my LARPers. Your methods are great for the armor we want to make! Thanks for all your help!

[@nxa4da]

Ted you are the king props! Thank you so much for your channel, you have inspired me so much and helped me create cosplays I never thought I would ever create. Thank you for teaching us!!

[@EvilTedSmith]

Thank you for watching and subscribing.

[@awaitingthetrumpetcall4529]

Developing this technique required creative genius. Well done.

[@EvilTedSmith]

Thank you very much!

[@blackthornejoshua2929]

Ted thank you so much I have had no luck making the helmet I talked with you about a year or so ago... it's so awesome you made this.. forever grateful

[@EvilTedSmith]

+Blackthorne Joshua You're welcome. I have a helmet pattern in my store eviltedsmith.com

[@spartanmc95]

great video as always, definitely going to be trying this when im back to working on/learning to build with foam

[@LunchbuttonFilms]

Awesome! That looks so good! Well done Ted!

[@terrykitchen5214]

I'm so impressed, I can't wait to try this stuff

[@taranzamybeloved8775]

Hi I'm stuff

[@michaelbenjamin3351]

THANKS A MILLION MR SMITH FOR SHARING & CARING STYROFOAM IS THE FUTURE MIKE

[@jakubtoporowski7784]

thank you for making easy to follow and detailed videos

[@crazyblazeX]

I'm addicted to your videos! Thank you so much!

[@EvilTedSmith]

+Hidekin Happy to hear it!

[@superstones7755]

Thank you for this! I'm really working to improve my pattern making skills! And why have I never thought to put the foam mat under the poster board! My pins will stay in so much happier now!! Thanks again!

[@EvilTedSmith]

+tricia stone You're welcome. Be sure to tell your friends.

[@ToastAndJellyfish]

Fantastic as always, Ted! Your videos are bar none the most helpful out there when it comes to foam fabrication. It would be awesome to see some sort of foundations series for basic shapes like this, I know one of my downfalls with my current project is getting spikes to look good, especially since I need the structure that comes from thicker foam. I'd love to be able to do them in a single wrapped piece but I can never seem to get them to come together cleanly.

[@Tara1978Tara]

Thank you so much for this video!! Your instructions are so clear and easy to follow. I wanted to make a faux Tiffany lamp shade out of a wire hanging flower basket and stained glass patterned window cling film and was having a really hard time figuring it out. I don’t think I could have pulled it off without your video.

[@EvilTedSmith]

Wonderful! That is my mission. To show others you can do it your self. All I asked is to tell like minded friends about me!

[@diegoamador7553]

Right when I needed this tutorial. Thank you!!

[@EvilTedSmith]

+Diego Amador You're welcome.

[@bocar4127]

I just used a bowl and thank goodness what I was going for has a flat top This method is so helpful!

[@masterpage69420]

Brilliant!! I'm making a costume of Earth and I need a sphere for it. Commander Holly mentioned your technique so I knew where to look

[@CafeNFTs]

Im loving this stuff!!!! Thank you!

[@EvilTedSmith]

Glad you enjoy it! I now have a dome pattern in my shop. eviltedsmith.com/shop/basic-dome-patterns/

[@CafeNFTs]

@@EvilTedSmith Thank you Ted! I'm going to check that out now. Would you happen to have an oval shaped template? It's going to be my first time building a helmet. I'm working on a semi big helmet that will be in the shape of a very large bean or grape. A big helmet like dj marshmallows but in a flying saucer grape shape. lol. Thanks a ton!....I'm on your site and found an egg pattern! Thanks a ton!

[@IRMAOCUSTOMMODELS]

Awesome tutorial. Thank you so much for sharring.

[@1234hellinthepacfic]

Hi Ted you have inspired me so much I am currently building a stormtrooper armour set from GRP Fibreglass so I am simultaneously building another suit from foam keep up the epic work

[@EvilTedSmith]

Thank you. As long as you keep watching.

[@curleyhurleyfosho]

Just discovered your channel and it's brilliant. Thank you, thank you, thank you!

[@EvilTedSmith]

Thank you for subscribing.

[@Carly-qr4pn]

Thank you for this tutorial!! regards from Chile!

[@danitanoumi940]

Evil Ted Love your video, I'm making a mandalorian helmet and this was exactly what I was looking for.... Thank you!

[@EvilTedSmith]

Thank you for subscribing.

[@mohammedsaif8945]

Thank you very much for the detailed and clear explanation

[@EvilTedSmith]

You're welcome. I have the pattern free on my site. eviltedsmith.com/product/basic-dome-patter/

[@mohammedsaif8945]

Evil Ted Smith Thanks for your quick response

[@DavidKimFX]

Thanks for demonstrating heat forming. There's been times after darting and gluing the pieces together where they've turned out flat and I wondered why. I was relying on the darting alone to reproduce curved surfaces.

[@EvilTedSmith]

Glad to help.

[@alyssa0411]

Thank you so much! My 12 year old has to design a Roman helmet with a strict limit of only $10 for a school project. All other online instructions and patterns i’ve seen want at least $8 which would blow the budget.

[@solypsomancer9540]

Mind-reader. I wanted to make a 1950's style space helmet. I thought about it a lot and mused as to what to do. Thank you for hauling off and doing it. I am going to order something through Amazon as a sign of gratitude.

[@EvilTedSmith]

+Yu Damman Thank you for subscribing. Shopping through my Amazon links help me keep making videos.

[@WilliamJakespeareProps]

that's brilliant!

[@EvilTedSmith]

+William Jakespeare Your brilliant for subscribing.

[@ianhamlett8839]

+Evil Ted Smith You're both brilliant.

[@sambeatty2312]

Notice me Daaaaad!!!!

[@carterkuntz5203]

William Jakespeare I love your vids

[@diddly-squat9332]

You're the Best Evil Ted!

[@EvilTedSmith]

+Shinichi Mizer Your the best for subscribing.

[@pinkyvince1972]

Thanks for all the tips !!!

[@EvilTedSmith]

+vincent demonfreid Thank you for subscribing.

[@PetterBruland]

Cooooool. Now I can start planning out R2-D2 and Bender :-)

[@Unwithe2bonnie]

Thank you so much man!! I found this very useful

[@EvilTedSmith]

Glad it helped!

[@edupuertasfruns]

So usefull, love it!!!!

[@daisyjano]

This is so helpful! I am making a cauldron shaped helmet (or a helmet shaped cauldron) for a play! Thanks so much!

[@EvilTedSmith]

Glad I could help!

[@ricardoneyra3220]

Gracias por compartir el tutorial, buenísimo.

[@jonbradley4789]

Well done sir. Very helpful!

[@EvilTedSmith]

Glad you enjoyed it!

[@TheArmoredGarage]

Great video Ted, some very clever tips in there!

[@EvilTedSmith]

+The Armored Garage Thank you Armored Garage.

[@Manuel_Z_Kayaks]

On your shoulder pattern at the end, your method works great but what I do differently is when I take the pattern and flip it to make the other side,I flip it but put it against the first pattern and "Butterfly" my patterns together to try and get rid of some of the center seam (Preferably no cut line from the most viewed side) Another thing I do is hit the glued edges with my heat gun, when it stops making bubbles it's ready to stick and sticks hard!

[@groundbreakerexplore]

Thank you so much for this tutorial video

[@EvilTedSmith]

Glad it was helpful!

[@SonAskani]

Looks nice. If you do domes often enough you could just make a jig with two small boards at 90 degrees and a 45 degree line in the middle. Mark on the edge, stick it into the corner where the boards meet, turn your mark so it sits jig line, and mark the other side where it sits on the jig line.

[@shittingmypant3709]

I needed this for a cosplay idk how it’s gonna turn out

[@roboninjasaur6729]

This has been a huge help thanks! :D

[@EvilTedSmith]

Happy to help. I have a new dome pattern in my shop now. eviltedsmith.com/shop/basic-dome-patterns/

[@roboninjasaur6729]

Ill check it out, thanks!

[@taintedshrimpz]

Badass dude.... friggin badass...

[@EvilTedSmith]

Thanks. I have the pattern for free on my site eviltedsmith.com

[@PictureJapan]

I'm doing costuming in my high school Art class and found wrapping a balloon in plastic wrap and tape also worked (they're not going to get perfect shapes the first time anyway). We didn't cut all the pieces separately, but instead cut darts and left them all connected in the middle. We used a heat gun to round out the center and glued the edges to continue the ball shape.

[@EvilTedSmith]

+PictureJapan Cool technique. Thank you for sharing.

[@andreamonk3464]

Genius!!!! Thank you so much

[@EvilTedSmith]

I am so happy that it helps. That is my mission is to make it easy for you to make your own stuff.

[@adamdenman3173]

Thanks I always wondered how to do that.

[@arekusogaki]

You are doing god's work Ted haha. I'm not super innovative or creative, so having some instruction like this is awesome for my cosplay needs :)

[@EvilTedSmith]

+TheOnlyLite Thank you.

[@Crousers1]

Mr. Smith your videos are amazing , and you have rly cool ideas :)

[@EvilTedSmith]

+JamesJackobGermany Thank you for subscribing.

[@Crousers1]

sure Mr. :)

[@lilmizzy2008]

Thanks for this! Making a bowsette costume and will be using this to make the back piece! 😊

[@EvilTedSmith]

Thank you for subscribing.

[@dawoodkuthub7181]

Explanation is simple to learn.

[@MelindaMonteverde]

yay !! just downloaded my template!!! will be using the cover page to make tiny Domes lol !!!

[@EvilTedSmith]

Great!

[@redtrooper9335]

That is so helpful! Thanks!

[@EvilTedSmith]

You're welcome.

[@jo3lsilvaracidesigner946]

Great Tips! thanks!

[@timzrcmore8020]

love this, I'll have to use it on my next bobs getting helmet

[@MadameMargherite]

This was great. Thanks.

[@EvilTedSmith]

Happy to help. I have a new dome pattern as well. eviltedsmith.com/shop/basic-dome-patterns/

[@KickapooNinja]

Nice techniques! I'm getting ready to make some Mandalorian armor out of PVC foam board for me and my daughter. I think I'll try this out and see if it works the same for the different material

[@gidgetsmart7186]

Did it work?

[@KickapooNinja]

@@gidgetsmart7186 yeah it worked pretty well, but now I think I'd rather go the 3D printed route. No reason in particular other than I've got a 3D printer now 😅 The "sintra" or PVC foam board is very easy to work with. Highly recommended.

[@cherrymeraki]

Super helpful, thank you!

[@EvilTedSmith]

Happy to help.

[@HYBECTIVE]

Thank you so much! I'm making an astronaut helmet and I've needed this exact method

[@EvilTedSmith]

Thank you for subscribing.

[@mountblanc39]

Great sir...

[@billybobbenjamin5343]

thank you, very helpful.

[@EvilTedSmith]

I am happy to help!

[@kalebwaters5771]

that is brilliant

[@EvilTedSmith]

+Kaleb Watets Thank you for subscribing.

[@Kikaimetsu]

Hey Ted. Got plans on making a leg armor tutorial? It would be appreciated!

[@cienfuegos569]

Perfect for my new project!!! R2D2 with foam. I only need to rescale the 10" dome pattern to 50% more. JAJAJAJAJA. Thanks for sharing Ted!

[@EvilTedSmith]

I have a new dome pattern as well. eviltedsmith.com/shop/basic-dome-patterns/

[@cienfuegos569]

I have bought it you some time ago. ;-)

[@cienfuegos569]

I´m little busy with the costume of gladiator. The Ridley Scott film. ;-)

[@jazeelocay9733]

Thanks mr. smith...

[@MrOngtrum1]

cool perfect circle

[@Gardardarri]

Hey man, great tutorials! I´m always confused what to buy exactly when it comes to foams and worbla stuff, if you could make like a short video on that, like what thickness are good for what and when you should use this foam or that foam. Look forward to your next tutorial.

[@EvilTedSmith]

+Gardar Darri You will learn faster by just building it. I can't make a video for eveyone out there. It's up to you now to make it!

[@roan5250]

Subscribed!

[@YossDome]

Love it

[@EvilTedSmith]

Thank you.

[@TheRandomHighFive]

awesome!

[@rajapakapavan6691]

good technics thanks

[@stephenhenley5586]

Thanks again, Ted.

[@EvilTedSmith]

Thank you for subscribing.

[@tth_awesomeplay7642]

OMG thx to you my riot helmet is done

[@omikronweapon]

informative video, but I was really looking for some way to make a shape without having the shape already. (If I already HAVE a cake, I can just eat it) Extra points for the shopping list though. Always nice to see that.

[@williamatkinson2382]

Awesome! I'll just hop on over to my pile of acrylic domes of my desired sizes for a template.

[@EvilTedSmith]

Or you can hop over to my new foam dome patterns. eviltedsmith.com/shop/basic-dome-patterns/

[@atitagain83]

You're the least Evil Ted I've ever encountered. Thanks for this in 2024.

[@igordewit7357]

Put the acrylic bowl upside down,level the new (open )topside,drop a bit of water in it.....there you go:thats the middle,the centerpoint. If can drill a little hole to transfer it to the other side..or hold the dome to the light,so you can see it.

[@Barbixas_pt]

Nice tips thanks!

[@EvilTedSmith]

Happy to help!

[@BPOnTheAir]

The background hum around the 9:00 mark sounds like Doc's oversized amp at the beginning of "Back to the Future."

[@berner]

Hey Evil Ted Smith, what do you think about the idea of using one of those chaulk lines that carpenters use when they need to mark lines on wood for 180 degree cuts?

[@ssssuhaillll]

wow!

[@EvilTedSmith]

Thanks!

[@jessiepayne9217]

Thanks im going to use this to make my own custom helmet

[@EvilTedSmith]

Go for it!

[@jessiepayne9217]

@@EvilTedSmith ok

[@HYBECTIVE]

Foam over a flame works very well also, just in case you don't have a heat gun

[@pedrolaragarcia]

To mark lines on a curved surface I believe it might come handy a piece of rope

[@monofelia]

I love this dome !! I can make a fine round head for my Cosplay now !! thank u !!

[@EvilTedSmith]

+ofe chan You should check out my How to Make a Foam Helmet video.

[@wowok7082]

thanks

[@omikronweapon]

7:52 "Topologists hate this guy"

[@tiffanyshackelford7125]

can you use your pattern enlargement technique to make larger domes than you buy in a store? say if we wanted to make this sucker 9ft. and a full sphere?

[@SuspiciousTumbleweedCos]

I totally forgot about flexible rulers.... There's one right over there too. It was just sitting there looking pretty.

[@DisneyUpBoilerUp]

I feel like I just watched a physics lecture, lol.

[@beachcomberbob3496]

I did leave a comment on another video, but it's better mentioned here. To mark a straight line over your dome, get yourself a spring steel spine out of a windshield wiper blade. You can clamp one end to your first mark, then bend it all the way over to the other side. Traditional thin ones will flex easier, but the thicker ones from the new frameless 'aero' blades will resist twisting, and give a truer straight line. Just slightly pre-form it first to the same radius as your dome, and you should be able to hold the second end in place with only thumb/finger pressure. Being metal, you can run a knife along it without damaging it and help you cut straighter lines.

[@EvilTedSmith]

Thanks for the tip!

[@beachcomberbob3496]

Evil Ted Smith It's the least I could do for all of the great stuff you've been teaching us. Keep on keeping on, brother!

[@soso41ui]

omg It's so helpful

[@EvilTedSmith]

+hansol Go OMG! You subscribed! Thank you.

[@protozoalord]

are you planning on making tutorials on shin and thigh armor?

[@bitweb]

Is it possible to Chrome the foam or give it that mirror chrome shine??? What would be the technigue? Awesome tutorial. Thanks

[@starshiptrooper9979]

Hey Ted, thanks a lot for your wonderful videos! I was wondering if you could tell us what the market name is for this type of foam. I would like try this tech with bigger projects and be able to find this type of foam in wholesale. Best regards!

[@BullDeerAryu_]

I'm using this to make a comically large spoon. Forget buying one, I'm just gonna make one.

[@EvilTedSmith]

YES! Just make it youe self!

[@ilikejazz8070]

Pls make a vid on how to make a swat riot costume pls!!!

[@Blackspire_Cosplay]

thank you for this great video. How did you end up attaching the 3 inch dome to the wood dowel?

[@EvilTedSmith]

5min epoxy glue.