Behind the Mask: A Look at Costuming Through Eyes of Foam

Armor

Helmets

Props and Accessories

Benefits Extremely lightweight Extremely lightweight Cheap Cheap Easy to find Easy to find Soft foams can be heat-shaped Soft foams can be heat-shaped Hard foams can be carved Hard foams can be carved Require no (or few) specialized tools Require no (or few) specialized tools

Drawbacks Can react badly with some paints and adhesives Can react badly with some paints and adhesives Surface can chip, dent, and scuff easily Surface can chip, dent, and scuff easily Even though it’s light, internal support structure is still needed for large pieces Even though it’s light, internal support structure is still needed for large pieces Static electricity makes clean-up of small pieces a real pain! Static electricity makes clean-up of small pieces a real pain!

Drawbacks

Basic Process Pattern Pattern Cut out pieces Cut out pieces Create curves, attach pieces together Create curves, attach pieces together Seal the foam Seal the foam Detailing, paint, finishing Detailing, paint, finishing

Craft Foam

Cut using sharp scissors or a craft knife Cut using sharp scissors or a craft knife

Craft Foam Heat-shape to produce curves Heat-shape to produce curves Heat Gun Heat Gun Iron Iron Stovetop Element Stovetop Element Hair Dryer Hair Dryer Oven Oven BE CAREFUL! BE CAREFUL! Try to form the shape on/around another object Try to form the shape on/around another object

Craft Foam Seal the foam Seal the foam For a hard, strong piece For a hard, strong piece Coat reverse with white glue Coat reverse with white glue Place layer of cheesecloth onto glue, pushing into corners and edges Place layer of cheesecloth onto glue, pushing into corners and edges When dry, trim edges flush, then add a second coat of glue When dry, trim edges flush, then add a second coat of glue Coat right side with diluted white glue and let dry Coat right side with diluted white glue and let dry Repeat to reinforce larger/protruding pieces Repeat to reinforce larger/protruding pieces

Craft Foam Seal the foam Seal the foam For a less rigid piece: For a less rigid piece: Use white glue or mod podge to coat foam (skip the cheesecloth step) Use white glue or mod podge to coat foam (skip the cheesecloth step) For a softer, more flexible piece: For a softer, more flexible piece: Use Flexbond adhesive to coat foam Use Flexbond adhesive to coat foam Best for smaller pieces or with good internal structure Best for smaller pieces or with good internal structure

Craft Foam

Paint Paint Water-based (acrylic, latex) tend to work best and are readily available Water-based (acrylic, latex) tend to work best and are readily available Use “puffy paint” for raised details Use “puffy paint” for raised details Can use rub-n-buff for metallic finish Can use rub-n-buff for metallic finish

Craft Foam