FRC FOAM GREY 2mm -High Density EVA Rubber-

FRC FOAM Grey 2mm is a high-density, high-quality EVA foam designed for making cosplay pieces, props and scenography with professional finishes. Its thin 2 mm thickness makes it the ideal choice for details, outer layers and pieces that require precision cutting, and it combines perfectly with thermoplastics such as Worbla or Thibra for even more elaborate results.

Technical specifications

What it is used for

FRC FOAM 2mm is the most versatile thickness in the range. Its high density allows clean cuts and precise heat moulding, making it especially useful for fine-detail pieces. Use it on its own or combine it with thicker sheets to create structures with volume and a professional finish.

• Armatures, helmets and cosplay accessories
• Props for film, theatre and television
• Scenography and set decoration
• Surface details on thicker pieces
• Templates and internal reinforcements in thermoplastic projects
• Scale models and lightweight prototypes
• Masks and heat-moulded facial pieces

How to use it

1. Design and pattern: draw or print the pattern for your piece on paper and transfer it to the FRC FOAM sheet using a marker or awl.
2. Cut: use scissors or a sharp craft knife following the pattern lines. A clean cut is key to well-fitting joints.
3. Thermoform: apply heat with a heat gun or heat stripper at a low distance to soften the foam. Shape it with your hands or over a mould and allow it to cool so the geometry sets. Use gloves if the piece is hot.
4. Bond: join the pieces with cyanoacrylate contact adhesive or a contact glue specifically formulated for EVA. Press firmly until it adheres.
5. Finish seams: lightly sand the seams with fine-grit sandpaper or a rotary tool at low speed. Always wear a dust mask when sanding to avoid inhaling EVA dust.
6. Paint: apply a coat of sealer or diluted PVA glue if you want a harder surface before painting. Then paint with acrylic paints or spray paint. EVA foam takes acrylic paint well directly on its surface.
7. Combine with thermoplastics (optional): for pieces with greater rigidity and detail, layer Worbla or Thibra over the thermoformed FRC FOAM.

Tips for use

Temperature and thermoforming

The 2 mm thickness heats up and cools down very quickly: work in small sections to maintain precise control over the final shape. If you need very pronounced curves, apply heat evenly across the back of the piece. Once the EVA has fully cooled — in just a few seconds in a cold environment — the shape is permanently set. If you are not happy with the result, you can reheat and redo it.

Finishing and painting

The surface of FRC FOAM has a slightly porous texture that takes acrylic paint very well directly. If you want a harder, shinier finish, first apply one or two coats of PVA glue diluted 50% with water, allowing each coat to dry before applying the next. For metallic effects or advanced patinas, use well-pigmented acrylic paints and apply with a sponge or dry brush to highlight the relief details.

Combining with other thicknesses and materials

FRC FOAM 2mm works very well as a detail layer over thicker bases. Combine it with FRC FOAM Grey 5mm or FRC FOAM Grey 10mm to build up structures with volume and add fine surface details. If you are working with thermoplastics, EVA acts as a lightweight, flexible inner fill that reduces the overall weight of the piece.

Frequently asked questions