FRC FOAM GREY 5mm -High Density EVA Rubber-

FRC FOAM Grey 5 mm is a high-density EVA foam (156 kg/m³) designed for cosplay construction, props and scenography. Its intermediate thickness makes it the most versatile option in the range: enough body for structured pieces, but with the flexibility needed to shape curves and complex forms with heat.

Technical specifications

What it's used for

FRC FOAM 5 mm is the go-to thickness for any handcraft project requiring pieces with their own volume. Its density clearly sets it apart from budget foams: it holds up to work, bonds well and accepts detailed finishes.

• Armour and breastplates for cosplay
• Helmets, shoulder guards and heat-moulded protection pieces
• Props and replicas of weapons, shields or accessories
• Theatre scenography and props
• Architectural models and volume prototypes
• Components combined with thermoplastics such as Worbla or Thibra for structural reinforcement and surface detail
• Bases and fills in special effects and character makeup

How to use it

1. Design and cut the pattern. Draw the pieces directly onto the sheet with a marker or pen. Cut with scissors or a sharp-bladed craft knife; the material gives without excessive effort.
2. Shape with heat. Apply a heat gun or hot air tool at a safe distance (10–15 cm) until the surface softens and becomes workable. Shape it with your hands or over a mould and hold the pressure until it cools.
3. Bond the pieces. Join the parts with cyanoacrylate contact adhesive or a contact glue specifically for EVA. Apply to both surfaces, allow the solvent to evaporate (if applicable) and press firmly.
4. Clean up the joints. Sand the joins with sandpaper or a rotary tool at low speed to remove steps and refine the finish. Always wear a dust mask when sanding.
5. Paint and finish. Apply a coat of flexible primer or latex before painting. Acrylic paints and water-based sprays adhere well to the prepared surface.

Usage tips

Moulding temperature

FRC FOAM 5 mm needs slightly more heat than the 2 mm version to soften uniformly throughout its full thickness. Work with the heat gun in constant motion to avoid burning the surface before the core becomes flexible. If you are moulding over a convex form (a helmet, for example), heat the outer face and try to keep the inner face in direct contact with the template for greater precision.

Combining with thermoplastics

The most professional result in cosplay armour is achieved by using 5 mm EVA as the structural base and covering detail areas with a thin layer of thermoplastic. The thermoplastic captures texture and surface relief while the EVA absorbs impacts and keeps the piece lightweight. Heat both materials before joining them for good adhesion without additional adhesive.

Painted and sealed finishes

The EVA surface is slightly porous and elastic, which can cause cracking if rigid paint is applied directly. Always prime with a coat of diluted latex, flexible primer or thinned PVA glue before painting. This seals the surface and creates a base that moves with the material without cracking.

Frequently asked questions

FRC FOAM for cosplay: the foundation of every armor

High-density EVA rubber FRC FOAM (156 kg/m³) is the starting material for most cosplay armor. It cuts with a utility knife, heat-forms with a heat gun and bonds with contact adhesive. Unlike craft foam, it holds its shape under heat, accepts texturing with thermal tools and survives an entire convention without warping.

• 2 mm — details, beveled edges, secondary layers and small pieces
• 5 mm — main armor panels: chest plates, bracers, greaves
• 10 mm — voluminous pieces: pauldrons, helmets and structural bases

For rigid armor with fine detail, combine it with Worbla Finest Art: encapsulate the foam between two layers of Worbla for rigidity with minimal weight. Add volume and three-dimensional textures with EVA AIR Foam Clay.