FRC FOAM BLACK 10mm -High Density EVA Rubber-

FRC FOAM Black 10mm is a high-density EVA foam (156 kg/m³) built for workshop use: it cuts cleanly, thermoforms with heat and accepts acrylic paint without primer. At 10 mm thick it is the most robust option in the range, perfect for cosplay structures, armour, volumetric props and scenography where you need body and rigidity without excess weight.

Technical specifications

What it is used for

FRC FOAM Black 10mm is the reference material in cosplay workshops and prop-making for its balance of rigidity, lightness and ease of handling. Its 10 mm thickness makes it especially suitable for pieces that need inherent volume without internal structures.

• Armour and breastplates for cosplay and LARP
• Helmets, shoulder pads and large-volume structural pieces
• Props and replicas of weapons, shields and prop objects
• Theatrical scenography and event sets
• Bases and substrates to combine with thermoplastics such as Worbla or Thibra
• Structural fill in volumetric figures and scale models
• Padding and cushioning in costumes and special wardrobe

How to use it

1. Design and pattern: draw the pieces on paper or cardboard and transfer them to the FRC FOAM sheet using a marker or fine-tip pen.
2. Cut: use a fresh-blade craft knife or sturdy scissors. For clean cuts in 10 mm, a precision knife with a metal guide gives the best results.
3. Thermoform: apply heat with a heat gun or hot-air stripper, keeping your distance to avoid burning the surface. EVA softens in seconds; shape it with your hands (protected) or over a form and hold it in position until it cools and the shape sets.
4. Bond: join the pieces with a cyanoacrylate or neoprene contact adhesive. Apply to both faces, leave to rest according to the adhesive instructions and press firmly.
5. Clean up the joints: once bonded, smooth and shape the joins with a rotary grinding tool or fine-grit sandpaper. Always work with a particle mask to avoid inhaling the dust generated.
6. Paint: apply acrylic paints by brush or spray directly onto the surface. For highly detailed finishes or realistic textures, combine FRC FOAM with Worbla or Thibra before painting.
7. Add final details: acrylic varnishes, patinas or primers increase finish durability and abrasion resistance.

Usage tips

Heat control when thermoforming

At 10 mm thick, FRC FOAM needs a little more heating time than thinner gauges. Move the heat gun in circles to heat evenly and avoid hot spots that burn the surface. If you need a sharp curve, heat in several short passes rather than one long one. Never hold the heat gun still over the EVA: the surface melts in seconds and the damage is irreversible.

Strong, clean bonding

For high-strength joins on large-volume pieces, neoprene contact adhesives work better than cyanoacrylates on wide surfaces. Apply a thin coat to both faces, wait until the adhesive is almost dry to the touch (between 3 and 5 minutes depending on ambient temperature) and join the pieces with firm pressure. Joints come out cleaner if you seal and sand the cut edge before bonding.

Surface preparation for painting

High-density FRC FOAM accepts acrylic paint directly, but a quick pass of heat over the surface before painting closes the micro-pores and improves adhesion. For metal-effect or worked-leather finishes, a flexible acrylic primer as a base extends the life of the finish and prevents cracking when the piece is flexed.

Frequently asked questions