Beginner's Armor Making with EVA Foam for Cosplay and Film

with Matthew Walther

On-Demand Access


  • 10+ Video lessons in HD
  • Exclusive bonus content
  • 30-day access to instructor
  • Over 10 hours of in-depth instructions
  • Lifetime access, anywhere, anytime
  • Available on desktop, mobile and tablet
  • 100% satisfaction guarantee

What you will learn:


Class 1:

  • Intro
  • About me

  • Why foam? (cost, availability, ease of use, lightweight)

  • Where to get it (hardware stores, online, etc.)

Class 2:

  • Tools and Shop
  • Shop safety and supplies

  • Tools list: Just starting out

  • Tools list: Upgrades!

  • Adhesives

Class 3:

  • Working with Foam
  • Straight cuts

  • Angled cuts

  • Bevels

  • Curves

  • Undercuts

  • Layering (stacking different thicknesses, offset edges)


Class 4:

  • Quick recap

  • What do you want to make?

  • Existing object: gather references

  • Personal or Concept design: sketch it out

  • Determine size, details, inner structure, etc. Mobility!

Class 5:

  • Pattern making: Pepakura

  • Difference of use (premade/downloaded vs. self-made, regular pep vs. foam pep)

  • Quick demonstration of unfolding a file

  • Organizing parts for printing

  • Overlapping pages

  • Pattern making: Freehand

  • Example with Ed Head

  • Mark center line

  • Sketch out base pattern (optionally able to make 2 different patterns on the same head) including hash marks for guides

  • Cut pattern carefully off the head

  • Transfer pattern to paper/card stock, watch for any needed darts

  • Extend patterns using hash marks to account for foam thickness

Class 6

  • Assembly

  • Trace patterns to foam and cut

  • Heat gun to shape hardest curves (knee anvil trick)

  • Contact cement, hair drier to speed up the process

  • Line up hash marks while attaching parts

  • Cut and assemble both helmet patterns (sci-fi style, fantasy style)


Class 7

  • Quick recap

  • Male vs. Female armor making

  • Shapes (stereotypes, ideas on how to break them)

  • Future vs. Fantasy

  • Historical vs. Fantasy

Class 8

  • Adding details: Sci-fi helmet

  • Layering

  • Holes: pipe

  • Rivets

  • Bevels

  • Tube port

  • Etched designs

  • Flip over for carbon fiber effect

Class 9:

  • Adding details: Fantasy helmet

  • Curved and organic crowns

  • Rear horn

  • Cut in crowns

  • Hammered textures

  • Cuts

  • Supports as necessary for open visor

  • Craft foam designs

About the course

Ever wanted to make a cool set of armor, and just didn't know how or didn't have the funds? This class is exactly what you need to get started. You will learn all about how to make armor with foam floor mats, or “EVA” foam, one of the easiest and least expensive ways to make amazing costumes and props with.

In this class you will learn how to work with the foam, including several tools you probably already have to work with it. You'll learn some basic pattern making, and how to cut, stack, sculpt, and etch your pieces to add huge amounts of detail you may never have thought possible. You'll also be able to follow along and make your own cool looking helmet, and then be able to apply what you've learned into making your own super cool set of armor!

Open Facebook Group to students of this course:
Curious Mondo: Beginner's Armor Making with EVA Foam

Time table:
9 hours

Basic / Intermediate / Advanced

Target market:
Anyone interested in making armor with foam, cosplay and film.

Main objective:
Learn all about how to make armor with foam floor mats.



About the instructor

Matthew Walther

Matthew has always loved building things, even at a young age. He caught the bug very early on, after attending local conventions for several years and seeing people dress up in costumes, though he never fully got into making his own costumes until a few years later, when he was introduced to the wonder that is foam fabrication.

In 2012, he made his first full set of armor out of foam floor mats and was hooked. Ever since then, he has cut thousands of pieces of foam and turned them into armor, weapons, and even gigantic costumes and creatures, always learning and improving his methods and skills.

Matthew has won several awards for his builds, including Best Video Game Representation, several Judge's Choice awards, and even Best Overall Master's Category for a costume he entered into the Intermediate Category. Participating in contests is just a fun side thing for him, however, since the more fulfilling thing for him is to share the things he has learned with other people who are interested in making something, but don't quite know where to start.

Armor Making with EVA Foam for Cosplay Sneak Peak


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