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FRC Foam Kit XS 10 & 5 mm -High Density EVA Rubber-
208251000
€40.00
48,40 € Tax incl.
48,40 € Tax incl.
FRC Foam sheets in XS format (47.5 × 27.5 cm), one 10 mm and one 5 mm, in white, black or grey, or a full kit with all 6 sheets in the three colours. High-density EVA foam (156 kg/m³), thermoformable and paintable.
The Kit FRC Foam XS combines the two most commonly used thicknesses in cosplay and prop making: a 10 mm sheet for structure and volume, and a 5 mm sheet for details, curves and small parts. High-density EVA foam (156 kg/m³) in XS format (47.5 × 27.5 cm), thermoformable, cuttable with a craft knife and paintable with acrylics without any primer.
Technical specifications
| Material | High-density EVA (ethylene-vinyl acetate) foam |
|---|---|
| Density | 156 kg/m³ |
| Shore Hardness | 30 – 35 |
| Included thicknesses | 10 mm and 5 mm (one sheet of each thickness per colour) |
| Format (XS) | 47.5 × 27.5 cm |
| Available colours | White, black and grey |
| Purchase options | White pack, black pack, grey pack or full kit (6 sheets) |
| Shipping | Rolled sheets |
What it is used for
The combination of 10 mm and 5 mm in a single kit covers the complete EVA piece-building process, from the base structure through to detail finishing. It is the usual starting point for those new to cosplay or prop making, and a convenient restock for those who already have an established workflow.
- Building armours, breastplates and structural pieces (10 mm)
- Details, reliefs, edges and curved pieces (5 mm)
- Helmets, shields and medium or small props
- Thermoformed masks and costume accessories
- Scale models, prototypes and rapid concept models
- Event decoration and window dressing
- Educational workshops and prop-making introductory courses
How to use it
- Choose the right thickness for each piece: use the 10 mm sheet for areas that need rigidity and volume, and the 5 mm sheet for details, flaps and tight curves.
- Draw or transfer the pattern: use transfer paper or a dry ballpoint pen on the foam surface. Measurements are approximate due to factory cutting, so bear this in mind when templating.
- Cut with a fresh craft knife blade: one clean stroke in a single pass. If the blade drags, change it. For curved cuts and small pieces, a scalpel or ergonomic-handle knife gives more control.
- Thermoform with a heat gun or iron: apply even heat to the area you want to curve and shape it with your hands or over a mould. The foam holds its shape as it cools. Do not overheat it — it loses density and deforms irreversibly.
- Bond pieces with contact adhesive: apply EVA Contact Pro to both surfaces, allow the solvent to flash off (the surface stops being shiny) and press firmly together.
- Paint directly with acrylics: no primer needed. For best results, apply a coat of flexible sealer before painting if you want a more durable finish or the piece will be bent.
- Add profiles and finishing touches: complement with the Kit de Perfiles EVA for edges, borders and linear elements.
Tips and tricks
Which colour to choose based on the final finish
Black is the most opaque and absorbs colours painted over it, making it ideal for dark finishes or for use unpainted. White and grey are the preferred base when painting in light or metallic tones, as they do not dull the colour. If you are painting with bright colours, always start with white or grey. The full kit includes all three options and lets you choose the most suitable base for each piece within the same project.
Thermoforming temperature
The optimal working range with a heat gun is between 60 and 80 °C at the foam surface. The higher the temperature, the more fluid and easy to curve the material becomes, but also more fragile and prone to bubbles. Keep the gun moving and work in zones. If you need to make very tight curves in the 10 mm sheet, heat the outside of the curve to avoid wrinkles on the inside.
Storage and transport
Store sheets horizontally on a flat surface, away from direct heat sources (sun, radiators). If you receive sheets with a slight curve from packaging, lay them flat with a weight on top for a few hours.
Frequently asked questions
Is primer needed before painting?
No. High-density FRC Foam EVA accepts acrylic paint directly on the surface without any primer. For pieces that will undergo heavy flexing or friction, it is advisable to apply a coat of flexible sealer to protect the finish and prevent paint cracking.
Which adhesive works best for bonding EVA foam pieces?
Contact adhesives are the most widely used in the workshop. EVA Contact Pro is specifically formulated for this material: apply to both surfaces, allow the solvent to flash off and press together firmly. The bond is immediate and flexible. Cyanoacrylate adhesives (superglue type) also work for small pieces, but the bond is rigid and may break when the material is bent.
Can the surface be sanded or textured?
Yes. High-density FRC Foam EVA can be sanded with fine-grit sandpaper to smooth edges or correct imperfections. It also accepts texturing with heat tools (hot metal tips, pyrography) to create surface reliefs and details. The high density of the material (156 kg/m³) makes for a cleaner finish than low-density foams.
What is the difference between the 10 mm and 5 mm sheet?
The 10 mm sheet provides structure, rigidity and volume: it is the base for armours, breastplates, helmets and large pieces. The 5 mm sheet is more flexible and easier to curve cold, making it ideal for details, edges, flaps and pieces with tight curves. In a typical build both are used: the 10 mm forms the body and the 5 mm adds details on top or in areas that need to conform to the body.
What size are the XS format sheets?
Each sheet measures approximately 47.5 × 27.5 cm. Measurements are approximate due to the factory cutting process. The XS format is the smallest in the FRC Foam range and is designed for medium-sized pieces, details and for those starting out or wanting to try the material with a smaller investment.
Does the kit include sheets in all thicknesses and colours?
The full kit includes 6 sheets: one 10 mm and one 5 mm in black, white and grey (two sheets per colour). Individual packs include only the two sheets (10 mm + 5 mm) in the selected colour. The kit is the most complete option for those starting out or wanting all three colours to match the base to the finish of each piece.
Can EVA foam be used to build a full mask?
Yes. The usual process is: design the pattern on paper, cut the pieces from the 5 mm sheet (easier to curve), thermoform with a heat gun adapting the shape to the face or a mould, bond with contact adhesive and paint with acrylics. For masks requiring more rigidity or volume in certain areas, 10 mm pieces are combined at the front with 5 mm on the sides and curved zones.
Is there an option to buy sheets of a single thickness only?
The Kit FRC Foam XS always includes both sheets (10 mm + 5 mm) per colour. If you need individual sheets of a single thickness in black, you can check the references FRC Foam Negra 10 mm and FRC Foam Negra 5 mm available in the Feroca catalogue.
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