EVA FOAM - GENERAL QUESTIONS

What is the difference between FOAM FORGE® EVA Foam and various other EVA foams from stores like Hobby Lobby?

While we can’t list comparison charts for every random competitor here, the main general difference is that FOAM FORGE® brand Ultra High-Density EVA Foams are true High Density products (coming in at 90+ kg/m3) that conform to our rigorous standards of quality.  Higher density usually means a better durability, more firm/rigid and less flexible, less potential for compression, and often a better outcome for costumes and props.  Many of our competitors list “High Density” as a meaningless buzz-word without having the density to back up those claims. For more information on "Ultra High-Density", please continue on to the next question.
We also offer larger sheets and thicker blocks than many of our competitors coming in at 1m² (40”²) and up to 50mm thick, meaning fewer seams for larger pieces like shields.

What do you mean by "Ultra High-Density" EVA foam and is it important?

One important way to measure foam (other than by its overall dimensions) is by its density.  The higher the density, the more material there is per square inch.  We take pride in our FOAM FORGE® Ultra High-Density EVA Foam products and we show it by listing the actual density on our packaging so you know you are getting quality and not meaningless buzz-words.  Many of our competitors list their EVA Foam as “High-Density” but can actually be as low as 30 kg/m3!  Our high-density foam products are a whopping 90+ kg/m3!
While there are definitely situations where low-density foam can come in handy, for cosplay crafting, high-density is the way to go.  Some of the key benefits are:
    • High-Density foams are usually more durable than low density.
    • Cutting and shaping High-Density foam is more precise.
    • Sanding High-Density foam results in smoother corners, edges, and surfaces.
    • High-Density foam can be more rigid and holds a form better than low, which is perfect for cosplay (especially armor and props).
    • Heat shaping High-Density foam is easier and holds a better final shape, meaning your outfit will stay in form longer!

I don't have a heat gun. Can I use a hair dryer to shape your foam instead?

Unfortunately, no. The heat output of household hair dryers range from 80-140 degrees Fahrenheit (26-60°C) while crafting heat guns range from 120-1100 degrees Fahrenheit (49-593°C). Manipulating EVA foam through heat requires higher temperatures than hair dryers are able to provide.

Why gray; and do you sell any other colors?

Why gray? We drew upon our color theory knowledge with this one to offer you the perfect color for crafting.  This neutral toned mid-gray is intended to allow you the best surface as a base layer to your painting.  While most foamsmiths and crafters will use a sealer and primer that will completely cover the foam material, a mid gray takes the majority of paint colors better than bright colors, white or black. It takes less paint and is easier to paint white on gray foam than black, and it is easier to paint black on gray foam than white.  We wanted to give you a completely neutral starting point for your paint layers.

Do we sell other colors? Although we are capable of manufacturing any color you can imagine, we currently only offer the FOAM FORGE® gray for our cosplay line of foam rolls, blocks, and Air-Dry foam clays.  If you need one or more custom colors for a project, please feel free to contact us to place a special order. Minimum quantities may apply to custom orders.

Is FOAM FORGE® EVA Foam waterproof?

Great question!  EVA foam by its nature is waterproof and repels water from its surface.  Even more, because EVA foam is created by trapping tiny air pockets in a special plastic material, EVA foam floats!  We do not recommend jumping into the pool in full EVA armor, but there are many cosplayers out there who have created water-based EVA foam costumes! It is recommended to always seal your foam pieces before attempting to submerge them in water.

What is the best type of paint to use on EVA Foam?

First off, if you are using this foam for cosplay costumes and props, we absolutely recommend sealing the foam before you attempt to paint it.  There are many different ways to seal, ranging from heat sealing (to pop the surface layer air pockets) all the way to using sealers like PlastiDip to really create a protective shell.
Following the sealer, we recommend priming the surface to help prepare the piece to bond to your paints.  Some sealants are so smooth that they do not offer a surface paint can stick to and you will find your hard work flaking off in the lease opportune times.
Once sealed and primed, we recommend your favorite acrylic paints to really bring your creation to life!

EVA FOAM - ROLLS & SHEETS

You sell your foam in rolls. Is there a way to make it lay flat?

Absolutely! If you purchased our FOAM FORGE® EVA Foam in our large rolls rather than in sheets or blocks, we recommend finding a large clean surface and stretching it out with semi-light weights on each corner. To expedite the settling process, we recommend doing this in sunlight or lightly going over the surface with a heat gun because heat helps relax the material.

EVA FOAM - BLOCKS

What if I need thicker foam than 50mm?  Do you offer any thicker sizes?

Unfortunately, we create these foam blocks in batches rather than piece by piece so, unless you are wanting to buy a large number of custom sized blocks, we will not be able to create small quantity orders at this time.