Lesson 1Tools and equipment: cutting tools (utility knives, rotary cutters, hot knives), heat tools (heat guns, thermoplastic molds), sanding tools, Dremel/rotary toolsGo over essential tools for cutting, shaping, and finishing EVA foam. Compare utility knives, rotary cutters, and hot knives, then look at heat guns, shaping forms, sanding blocks, and rotary tools, with advice on safe handling, maintenance, and achieving neat results in your workshop.
Utility knives, blades, and safe cutting habitsRotary cutters and cutting mats for clean edgesHot knives and heated blades for dense foamHeat guns, shaping forms, and controlled heatingHand sanding blocks, files, and sanding spongesDremel and rotary bits for carving and bevelsLesson 2Safety gear and workshop setup: ventilation, respirators vs. dust masks, gloves, eye protection, fire safety, safe storage of flammablesLearn to set up a safe workspace for EVA foam work. Topics cover ventilation for fumes and dust, respirators compared to dust masks, gloves and eye protection, fire safety with heat tools, and proper storage of flammable coatings, solvents, and glues to keep your area secure.
Ventilation strategies for fumes and dustRespirators, cartridges, and dust masksGloves, eye protection, and clothing choicesHeat gun, hot tool, and fire safety basicsStoring flammable paints, glues, and solventsLesson 3Complementary materials: craft foams, foam board, lightweight armatures (PVC, balsa, aluminum), filler foams, and structural coresLook at additional materials that enhance or support EVA foam builds. You will compare craft foam, foam board, PVC and balsa armatures, aluminium wire, filler foams, and structural cores, with tips on securely attaching them to EVA surfaces for sturdy results.
Craft foam sheets for detail layeringFoam board for lightweight internal wallsPVC pipe armatures for large propsBalsa wood and dowels for light framingAluminum wire and mesh for poseable formsFiller foams for gaps, voids, and carvingLesson 4Paint systems: flexible acrylics, airbrush-ready paints, pigment types, UV-resistant topcoats, mixing and thinning guidanceDiscover flexible paint options for EVA foam, from brush-on acrylics to airbrush mixes. Learn about pigment choices, thinning ratios, layering techniques, and UV-resistant topcoats that prevent cracking while keeping surface details and flexibility intact for long-lasting pieces.
Choosing flexible acrylic and vinyl paintsAirbrush-ready paints and proper thinningPigment types, opacity, and colorfastnessLayering, curing times, and recoat windowsUV-resistant clear coats and topcoat choicesLesson 5Adhesives and solvents: contact cement, hot glue, neoprene glue, PVA for mixed materials, solvent compatibility and jointsExamine glue and solvent choices for EVA foam, including contact cement, hot glue, neoprene glue, and PVA for combining materials. Learn surface preparation, open time, clamping methods, and solvent compatibility to form strong, flexible, and clean joints that hold up well.
Contact cement types and safe applicationHot glue for tacking, filling, and quick joinsNeoprene and flexible glues for stress pointsUsing PVA with paper, fabric, and foam mixesSolvent safety, ventilation, and cleanupLesson 6Closed-cell vs. open-cell foams, cross-linked foam variants, and recommended brands/material codesDistinguish between closed-cell and open-cell foams, including cross-linked EVA types. You will understand how structure influences absorption, flexibility, sanding, and coating, and review popular brand names and material codes commonly used by local builders in Namibia.
Closed-cell foam traits and ideal usesOpen-cell foam behavior and limitationsCross-linked EVA and premium sheet optionsReading density, shore, and supplier codesPopular cosplay and craft foam brandsLesson 7EVA foam densities, thickness ranges, and trade-offs for sculpture (2mm–20mm)Grasp EVA foam density and thickness choices from 2 mm to 20 mm and more. Learn how density, hardness, and sheet size impact carving detail, weight, durability, and cost, helping you select foam specs for armour, props, and sculptures suited to your needs.
Density ratings, hardness, and compressionCommon thickness ranges from 2 mm to 20 mmChoosing foam for armor, props, and basesBalancing weight, rigidity, and flexibilityLamination techniques to build custom thicknessLesson 8Coatings and sealers: plastidip, flexible acrylic sealers, PVA primers, epoxy coats—advantages, flexibility, durabilityCompare typical EVA foam coatings and sealers like Plasti Dip, flexible acrylic sealers, PVA primers, and epoxy. Learn their effects on flexibility, durability, sanding, and paint adhesion, plus when to layer or mix products safely for robust finishes.
Plasti Dip pros, cons, and application tipsFlexible acrylic sealers and brush techniquesUsing PVA glue as a primer on EVA foamEpoxy coats for impact resistance and glossLayering sealers without cracking or peeling
