Choosing the Best Materials for Your Cosplay Armor

Skillful young woman in apron painting at workshop

Crafting screen-accurate and visually stunning costume armor can be a complex endeavor. To bring these characters to life, cosplayers employ a wide range of materials, each with its unique properties and advantages.

The choice of materials for your costume project depends on factors such as budget, access to crafting tools and workspaces, and your willingness to learn and work with unfamiliar materials.

5 Considerations For Choosing Costume Materials

Here are five of the most important things to consider when choosing costume materials:

  1. Set your budget. Every project will be limited by how much money you want to spend, and it’s important to understand when and where it’s appropriate to use cheaper materials to keep costs down. You can always upgrade your materials later!
  2. Evaluate your tools. Some materials require expensive tools to work with (3D printing sounds great until you have to buy an expensive new printer), while others can be used with common household items (scissors, utility knives or even a hair dryer). See what tools you own and know how to use before selecting your materials.
  3. Consider your workspace. Do you have enough room to craft? Do you have a safe space to work with hazardous materials like adhesives, paints and 3D printing filaments and resins that produce harmful fumes? Can you keep toxic or dangerous materials away from your children or pets?
  4. Contemplate your comfort. Cosplay armor made of metal or other heavy materials sounds great until you realize how bulky it can be to wear. You should also consider which materials might help keep you from overheating or allow for greater range of movement and flexibility while being worn.
  5. Decide your accuracy. If you’re cosplaying an existing character, how close do you want your costume to directly reflect their look? Screen-accurate props can be recreated, but often at a steep price. Do you really need to use the exact materials used by others, or are you happy with similar-looking alternatives?

Popular Armor Crafting Materials

While you plan out your costume build, it’s also important to research what materials are readily available and are being used by other creators making similar projects. Some of the most popular cosplay armor crafting materials include:

Creality 3D printer
Elegoo Saturn 2 resin 3D printer

3D Printing

In recent years, the advent of 3D printing technology has revolutionized cosplay armor creation. Using CAD software, cosplayers can design intricate armor pieces and print them layer by layer on an FDM printer using thermoplastic filament like PLA, ABS or PETG, or via SLA and DLP printers that use high-resolution resins. 3D printing allows for precise replication of complex designs and provides opportunities for customization and experimentation.

Pros: Perfect for producing highly-accurate parts without having to manually shape each by hand. Printable models for popular characters likely already exist.
Cons: Expensive tools that require some technical skill; Strong fumes require ventilation and safety materials. Not an option if 3D models of your parts aren’t available or you can’t create your own. I hope you like sanding.

Creality 3D printer
Elegoo Saturn 2 resin 3D printer


Worbla, a thermoplastic material, gained popularity with cosplayers due to its versatility and ease of use. It becomes pliable when heated, allowing artists to mold and shape it according to their requirements. Worbla is lightweight, relatively durable and can be seamlessly joined with heat. Its paintability and ability to hold intricate details make it ideal for crafting armor pieces that demand precision.

Pros: Nontoxic material that can be shaped into complex forms or wrapped around lightweight cosplay materials.
Cons: Comparatively expensive. Requires some artistic ability to shape. Sensitive to warping in extreme heat, like in a hot car. Some types need sanding for a smooth finish.

Creality 3D printer
Elegoo Saturn 2 resin 3D printer

EVA Foam

EVA (Ethylene-Vinyl Acetate) foam is another widely used material in the cosplay community, beloved for its affordability and accessibility. This foam can be bought in various thicknesses and densities, making it suitable for crafting armor of different types and sizes. With its shock-absorbing properties, EVA foam is lightweight, easy to cut, and comfortable to wear. It can be heat-formed, engraved, and textured to resemble various materials like metal, leather or scales.

Pros: Inexpensive and widely available. Lightweight and relatively easy to work with for beginners. Comfortable to wear and can be used as padding inside other materials.
Cons: Not as durable as thermoplastics and prone to damage with rough handling. Vulnerable to moisture and extreme heat. Can be more difficult to achieve smooth surfaces for painting.

Other Cosplay Materials:

Fiberglass and Resin: For those aiming for a more robust and realistic finish, fiberglass and resin are excellent choices. Fiberglass, when combined with resin, creates a sturdy and lightweight armor piece. It requires some skill and safety precautions during fabrication, as it involves working with potentially harmful chemicals and materials. However, the end result can be incredibly impressive and long-lasting.

Other Thermoplastics: Apart from Worbla, other thermoplastics like Sintra, Kydex, and PETG are popular choices for creating cosplay armor. Sintra is a rigid expanded PVC sheet that can be shaped using heat, while Kydex is a durable and rigid thermoplastic often used for holster-making. PETG (Polyethylene Terephthalate Glycol) is a clear thermoplastic that can be vacuum-formed to create transparent visors or helmet lenses.

Foam Clay and Apoxie Sculpt: For cosplayers seeking materials that combine flexibility with sculpting capabilities, foam clay and Apoxie Sculpt are worth considering. Foam clay is a lightweight, air-drying clay that adheres well to various surfaces. It can be used to add intricate details and textures to armor pieces. Apoxie Sculpt, a two-part epoxy clay, provides a strong and durable finish. It can be shaped, sanded, and painted, making it suitable for sculpting and adding fine details.

Choosing Materials That Are Right For You

The realm of cosplay armor materials is rich with options, each offering unique benefits and challenges. From the malleability of thermoplastics, to the affordability of EVA foam and the precision of 3D printing, cosplayers have a vast array of choices to suit their desired aesthetics and skill levels. By exploring and experimenting with these materials, cosplayers can bring their favorite characters to life and make their mark in the vibrant world of cosplay.

Your cosplay project should incorporate different types of materials depending on the desired look and purpose of each piece of your costume. Do not be afraid to get creative with alternative crafting materials and remember that you can always upgrade pieces of your gear as your budget allows and your crafting skills improve.

So, unleash your creativity, choose your armor material wisely and embark on an exciting cosplay adventure like no other!

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