Lesson 1Tools and equipment: cutting tools (utility knives, rotary cutters, hot knives), heat tools (heat guns, thermoplastic moulds), sanding tools, Dremel/rotary toolsReview essential cutting, shaping, and finishing tools for EVA foam. Compare knives, rotary cutters, and hot knives, then move to heat guns, shaping forms, sanding blocks, and rotary tools, with tips for safe use, upkeep, and clean results.
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 how to set up a safer EVA foam workspace. Topics include ventilation for fumes and dust, respirators versus masks, gloves and eye protection, fire safety around heat tools, and correct 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 3Complementary materials: craft foams, foam board, lightweight armatures (PVC, balsa, aluminium), filler foams, and structural coresSurvey complementary materials that strengthen or refine EVA builds. You'll compare craft foam, foam board, PVC and balsa armatures, aluminium wire, filler foams, and structural cores, with guidance on bonding them securely to EVA surfaces.
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 guidanceExplore flexible paint systems for EVA foam, from brush acrylics to airbrush-ready mixes. Learn pigment choices, thinning ratios, layering methods, and UV-safe topcoats that resist cracking while preserving surface detail and flexibility.
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 adhesive and solvent options for EVA foam, including contact cement, hot glue, neoprene glue, and PVA for mixed materials. Learn surface prep, open time, clamping, and solvent compatibility to create 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 codesDifferentiate closed-cell and open-cell foams, plus cross-linked EVA variants. You'll learn how structure affects absorption, flexibility, sanding, and coating behaviour, and review common brand names and material codes used by builders.
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)Understand EVA foam density and thickness options from 2 mm to 20 mm and beyond. Learn how density, hardness, and sheet size affect carving detail, weight, durability, and cost so you can match foam specs to armour, props, and sculpture.
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 common EVA foam coatings and sealers, including 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 products 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
