Lesson 1Tools and Equipment: Cutting Tools (Utility Knives, Rotary Cutters, Hot Knives), Heat Tools (Heat Guns, Thermoplastic Moulds), Sanding Tools, Dremel/Rotary ToolsGo over essential tools for cutting, shaping, and finishing EVA foam. Compare knives, rotary cutters, and hot knives, then look at heat guns, shaping forms, sanding blocks, and rotary tools, with tips for safe use, maintenance, and neat results.
Utility knives, blades, and safe cutting practicesRotary cutters and cutting mats for clean edgesHot knives and heated blades for thick foamHeat guns, shaping forms, and controlled heatingHand sanding blocks, files, and sanding spongesDremel and rotary bits for carving and edgesLesson 2Safety Gear and Workshop Setup: Ventilation, Respirators vs Dust Masks, Gloves, Eye Protection, Fire Safety, Safe Storage of FlammablesLearn to set up a safer workspace for EVA foam work. Topics cover ventilation for fumes and dust, respirators versus masks, gloves and eye protection, fire safety with heat tools, and proper storage of flammable coatings, solvents, and glues.
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 3Other Materials: Craft Foams, Foam Board, Lightweight Frames (PVC, Balsa, Aluminium), Filler Foams, and Structural CoresLook at other materials that strengthen or improve EVA builds. You will compare craft foam, foam board, PVC and balsa frames, aluminium wire, filler foams, and structural cores, with advice on bonding them well to EVA surfaces.
Craft foam sheets for detail layeringFoam board for lightweight inner wallsPVC pipe frames for big propsBalsa wood and dowels for light framingAluminium wire and mesh for flexible formsFiller foams for gaps, holes, and carvingLesson 4Paint Systems: Flexible Acrylics, Airbrush-Ready Paints, Pigment Types, UV-Resistant Topcoats, Mixing and Thinning TipsExplore flexible paint options for EVA foam, from brush-on acrylics to airbrush mixes. Learn about pigment choices, thinning ratios, layering methods, and UV-safe topcoats that avoid cracking while keeping surface details and flexibility.
Choosing flexible acrylic and vinyl paintsAirbrush-ready paints and proper thinningPigment types, opacity, and colour fastnessLayering, curing times, and recoat windowsUV-resistant clear coats and topcoat choicesLesson 5Glues and Solvents: Contact Cement, Hot Glue, Neoprene Glue, PVA for Mixed Materials, Solvent Compatibility and JointsCheck out glue and solvent choices for EVA foam, including contact cement, hot glue, neoprene glue, and PVA for mixed materials. Learn surface prep, open time, clamping, and solvent compatibility for strong, flexible, clean joints.
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 CodesTell apart closed-cell and open-cell foams, plus cross-linked EVA types. You will learn how structure affects absorption, flexibility, sanding, and coating, and review common brand names and material codes used by makers.
Closed-cell foam traits and ideal usesOpen-cell foam behaviour 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)Understand EVA foam density and thickness from 2 mm to 20 mm and more. Learn how density, hardness, and sheet size affect carving detail, weight, durability, and cost so you can match foam to armour, props, and sculpture.
Density ratings, hardness, and compressionCommon thickness ranges from 2 mm to 20 mmChoosing foam for armour, 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 common EVA foam coatings and sealers, like Plasti Dip, flexible acrylic sealers, PVA primers, and epoxy. Learn how each affects flexibility, durability, sanding, and paint adhesion, plus when to layer or combine safely.
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
