Cosplay is a popular hobby amongst people who love dressing up as their favorite characters from movies, TV shows, comics, and video games. It requires an immense amount of creativity, skill, and dedication to making your costumes look as realistic as possible. One of the most important components of cosplay is the armor – whether it’s made out of foam or metal – which can help you achieve a more accurate look. In this article, we will discuss what materials and tools are used to make armor pieces for cosplay costumes and how to go about making them step-by-step. We will also provide some tips on how to get the perfect finish for your armor piece so that you can stand out at any convention!

What is Cosplay?

Cosplay is a portmanteau of “costume play” and involves dressing up as a character from pop cultures such as movies, TV shows, comics, or video games. It has become increasingly popular over the last few years due to its creative nature – allowing people to express themselves through their chosen character’s costume design. Cosplayers often spend months (sometimes even years) perfecting their costumes before attending conventions or events where they can show off their work.

Different Types of Armor in Cosplay:

There are many different types of armor used in cosplay costumes depending on the character being portrayed. Some examples include full-body armor (like knights), lightweight leather armor (like elves), sci-fi-inspired pieces (like space marines), or fantastical creature designs (like dragons). The type of armor used depends entirely on the character being portrayed – but all require some level of skill and craftsmanship when creating them from scratch.

Materials Used for Making Armor:

When it comes to making armor pieces for cosplay costumes several different materials can be used depending on the desired effect. Foam is one of the most commonly used materials due to its affordability and ease of use when cutting and shaping into various shapes and sizes. Worbla/thermoplastics are also popular due to their durability and ability to be heat molded into any shape desired – although they can be quite expensive compared to foam options.

EVA foam mats are another great option for those looking for something lightweight yet durable enough for long periods of wear without compromising on comfort or accuracy in design details like rivets or straps etc. Leather and fabric can also be used if you want something that looks more realistic but may require more time spent crafting each piece since it needs sewing together by hand instead of simply cutting with scissors like with foam options etc. Waxed canvas or duck cloth can also be used if you want something with an aged look that doesn’t require much maintenance over time – just remember not to get it wet!

Finally metal, wood, and resin casting are all excellent choices if you want something more durable than foam but still lightweight enough not to weigh down your costume too much during wear, etc.

Tools Used To Make Armor Pieces:

In addition to the various materials available, there are also several tools needed when crafting armor pieces from scratch such as a heat gun/hair dryer which helps soften certain materials like thermoplastics so they can be molded into any desired shape; a utility knife/box cutter which is great for cutting through thicker materials like leather; a hot glue gun; sandpaper/files; paint brushes/spray paint; pliers; a Dremel; etc. All these tools should help make creating your custom pieces easier while ensuring accuracy in design details like rivets or straps etc.

How To Make Armor Pieces Step by Step:

Once you have gathered all your materials and tools then it’s time to start making your custom pieces! Begin by sketching out your design onto paper then trace it onto whatever material you plan on using – either foam sheets or leather depending on what kind of effect you want – then cut out each piece using either scissors or a utility knife/box cutter depending on how thick the material is. Once all your pieces have been cut out then use either hot glue or thermoplastic molding techniques – along with clamps if necessary – to attach them until they form one complete piece then leave them aside until cooled completely before moving on painting, etc.

Finishing Touches For Your Armor Piece:

Once all your pieces have been attached then it’s time for the finishing touches! Depending on what kind of effect you are going for this could involve spray painting certain areas with metallic colors like silver or gold – adding straps made out of leather/fabric – adding rivets made out of plastic sheets heated with a heat gun/hair dryer – adding gems made out air dry clay painted with acrylic paints – adding weathering effects using black acrylic paint mixed with water – adding small details using wire mesh, etc. Whatever kind of effect you choose make sure everything is sealed properly so that moisture doesn’t damage any part of your costume during wear!

Tips For Making The Perfect Cosplay Armor:

Making perfect cosplay armor requires patience, skill, creativity – but most importantly knowledge! Before starting you must familiarize yourself with all the different types of materials available so you know which one best suits your desired effect then research what tools might be needed when crafting each piece such as a heat gun/hair dryer if using thermoplastics etc. Additionally, try experimenting with different techniques such as weathering effects using black acrylic paint mixed with water – these small details can help bring life into otherwise dull-looking armors!

Finally don’t forget about safety precautions when working with sharp objects like utility knives/box cutters – always wear protective gloves when handling these tools!


Creating custom armors for cosplay costumes requires skill and dedication but once completed they can help bring life into otherwise dull-looking characters! In this article, we discussed what materials and tools are needed when making armors from scratch along with step-by-step instructions on how best to go about doing so plus some tips on how to get the perfect finish for your costume piece. Now that you know how to make armor why not check out Kiguki fashion products? We offer an array of stylish clothes suitable for both daily wear and special occasions alike – perfect for those wanting to express themselves through fashion whatever occasion may arise!


What material do cosplayers use?

Craft foam is one of the most commonly used materials for making props. Such lighters are relatively inexpensive and readily available from suppliers in North America and Europe. It comes in large sheets and is the basis for most of the sword and armor pieces you see at conventions.

What kind of foam to use for cosplay armor?

EVA Foam
EVA Foam is a great material for constructing costumes and props of all different kinds, from period armor and swords to slick futuristic robots. It is especially beloved by cosplayers and prop makers because it is lightweight, cheap, and can easily be cut, carved, and even heat shaped to create interesting forms.

What is the best material to make a cosplay helmet?

EVA foam
EVA foam is the perfect material for making a cosplay helmet. If you’re new to making your cosplay props, a helmet is one of the simplest places to start. EVA foam is an ideal material for your cosplay helmet, since it’s pliable and easy to shape using hand tools like a craft knife.

What thickness foam is best for cosplay armor?

We recommend getting one or two sheets of 0.25-inch thick foam for your cosplay weapon.

How thick should EVA foam be for armor?

between 4mm-6mm
EVA 38 Foam: Foamsmiths tend to choose this type of foam for most armor creation, as it has a great combination of flexibility, durability, and cost efficiency. A favored thickness for most armor is between 4mm-6mm with thinner rolls used in detail work and thicker rolls for chunkier props, panels, and details.

Does hobby lobby carry EVA foam?

Black Cosplay High-Density EVA Foam – 10mm | Hobby Lobby | 80982131.