EVA foam: the starting point for most builds

EVA foam is cheap, forgiving, and available everywhere. TNT Cosplay Supply and SKS Props sell cosplay-grade sheets. Harbor Freight anti-fatigue mats work for budget builds. Standard thickness is 6mm for armor panels, 2mm for detail layers.

• 2mm for details, trim, and surface accents ($3 to $5 per sheet).
• 6mm for standard armor panels and pauldrons ($6 to $8 per sheet).
• 10mm for structural pieces, shields, and thick armor ($8 to $12 per sheet).
• Always seal foam before painting. FlexBond or Plasti Dip prevent paint absorption.

Adhesives: the bond matters more than the material

Barge All-Purpose Cement is the community standard for structural foam bonds. Apply to both surfaces, wait until tacky, press once. The bond is permanent. DAP Weldwood is a cheaper alternative. Hot glue works for quick tacks but melts at outdoor summer conventions.

• Barge cement: $15 to $20, permanent structural bonds.
• DAP Weldwood: $8 to $12, slightly weaker but fine for most builds.
• E6000: $5 to $8, flexible industrial adhesive for detail work.
• Hot glue: instant but brittle and heat-sensitive. Not for structural use.

Paints and finishes that photograph well

Acrylic craft paints ($1 to $3 each) handle base coats. Spray paints give even coverage on large pieces. Rub 'n Buff metallic wax is the easiest way to make foam look like real metal. Weathering washes (thinned black or brown acrylic in crevices) are the single biggest upgrade to any armor paint job.