10 cosplay (and LARP) materials you absolutely must try
"What's that made of?"
That's often the first question I ask myself whenever I see a costume that blows me away. Even before wanting to know who made it or where the inspiration came from, I want to know what it was made with.
Whether it's for cosplay or LARP, material isn't just a detail, it's what changes everything about the final result.
Over the years, I've tried quite a lot of things. Some have become staples of my workshop, and others just options I use less often. Either way, they're all worth trying at least once, to discover new possibilities, different alternatives... because every new material teaches you something about how you create.
Here's my top 10. And for each one, what I love, what I love less, and why it's worth the detour.
EVA foam
If you make accessories, you probably already know it's a staple. A flexible, lightweight, cheap, and super versatile material. It's perfect for lightweight armor, accessories with really impressive shapes, helmets, weapons, etc.
What I love about EVA foam is that it's not just an accessory material. I often use it in costumes too. Especially thin EVA foam, like 2mm (also called craft foam). It holds up better than fabric, but keeps a flexibility that rigid interfacing doesn't have.
Plus, you can easily sew through it. So you can cover foam pieces with fabric, sew right through them, and everything (like the logo on the Superman costume below). You can get some really nice textures that way.
| If you want to go further with EVA foam, I'd recommend my intro article on this material. |
- Why we love it: It's cheap and easy to use.
- Its limits: It doesn't breathe (you get REALLY hot in a suit of EVA foam armor).
Worth trying if you're building armor, but also for creating layered textures.
Worbla
I love Worbla. If you're not familiar with it, it's a non-toxic, thermoformable material (meaning you can shape it with heat) that comes in large rigid sheets you can cut with scissors and mold with a heat gun. Plus, it sticks (and even fuses) to itself. No adhesive needed to join Worbla to Worbla.
I mainly use this material to reinforce elements.
But what I love most is that you can use up every last bit of the material. So I keep all my scraps, because I can heat them up, mash them together, and work the whole thing like a kind of stiff modeling clay. It's awesome for adding details or making small pieces.
My biggest complaint (besides the fact that it's really expensive) is that, since it molds at a fairly low temperature, it's a material that doesn't handle long sun exposure and intense summer heat very well. That means it's probably not a great fit for summer LARPs (I wouldn't want to spend hours and hours in the sun with a Worbla accessory, let's say). And it also means that if you forget a piece in your car in the middle of summer, it'll collapse in on itself, stick together (since Worbla sticks to itself), and you'll definitely have to say goodbye to it.
- Why we love it: It's non-toxic and (almost) endlessly reusable.
- Its limits: Its sensitivity to summer heat.
Worth trying for the fun of working with a thermoformable material and for making details out of the scraps.
Upholstery foam
If you're into mascots or dream of doing a Pokémon cosplay, you need to try upholstery foam. I used it for the first time in 2019 for the Yoshi cosplay I made… and I fell in love. First because it's worked in a pretty different way from everything else. But also because it always makes such fun, ridiculous things. What can I say, making an oversized giant head just puts me in a good mood.
Honestly, it's fun. But it's also really impressive. Because you can make huge, ultra-lightweight shapes.
You can work it a bit like EVA foam, assembling pieces to create an "empty" volume. But you can also stack layers and then sculpt the shape you want. Which gives you a "solid" volume.
Either way, it's generally better to cover your upholstery foam piece (unlike EVA foam, which can just be painted). But the texture is really different. It makes big, plush things. Like giant stuffed animals.
| If you want to learn more about this foam, I'd recommend my blog article on mascots |
- Why we love it: It's super light and plush
- Its limits: It's not a material suited to fine details.
Worth trying just to see how much fun it is.
Window screen mesh
Since I'm on the topic of making big improbable shapes, window screen mesh is a real must try. It's a material that's sometimes underrated, but it can really come in handy in all kinds of situations.
*But you need to be careful, there are 2 types of screen mesh: metal and fiberglass. I strongly recommend the fiberglass one. Much easier to handle, way less chance of getting little metal bits stuck in your hands, zero chance of rust… and on top of that, you can sew it! Cool, right?
I really love using this material for making super lightweight structures that breathe (that's a big advantage over a lot of other materials). Base for a turban, a big wig, or a hat with an improbable shape, you can easily build a support that's light, flexible, and that you can sew or glue your covering materials onto.
It's also a really handy material for making mascot eyes (you'll want to try it combined with upholstery foam!)
- Why we love it: It's super light and easy to handle.
- Its limits: Be careful not to cover it with materials that are too heavy.
Worth trying for making structures to cover… that breathe.
Metallic lycra
There are 2 absolutely awesome things about metallic lycra. It's super stretchy. And it's super shiny. It's a great fabric for making superhero outfits (you know, the classic comic book versions). Or mermaid tails. Or anything you want to make super glam.
If you're even a little comfortable with lycra and other knits, you shouldn't have too much trouble sewing this one. So don't be afraid, and enjoy the beautiful textures.
But what's also really cool about metallic lycra is that you can use it to cover foam. Earlier, I mentioned using EVA foam to create layered textures on a costume (like for the Superman emblem). To cover it and keep as much texture as possible, you need a stretchy fabric. And the combo of EVA foam plus stretch lycra is just amazing.
Yes, you can use plain lycra. But metallic lycra will give you a texture you won't find anywhere else. Honestly, it's worth trying.
- Why we love it: Its metallic effect easily transforms a piece.
- Its limits: Be careful with storage, the metallic effect can stick to itself, crack, or peel off the fabric.
Worth trying for the incredible colors and to add some shine to your life.
3D printing
I know, it's not really a material, more of a technique... but I still felt it deserved a spot on this list.
There's a whole (and growing) range of materials you can use with a 3D printer, but the most common one (and the one I'd recommend if you're just starting out) is PLA.
Of course, there's a significant upfront investment. To 3D print, you need the printer. But it's a technique that's really become accessible in recent years, and 3D printers keep getting cheaper.
What's great about 3D printing is that, with the right file, you can create super precise pieces (even if you're not the most manually skilled person): accessories, jewelry, helmets, etc. the possibilities are basically endless.
| Want to get into 3D printing? I'd recommend the guide: How to Make a Good Impression |
- Why we love it: 3D printing offers incredible precision.
- Its limits: You need to find THE right file (or learn 3D modeling).
Worth trying to create a very precise accessory that would be hard to sculpt otherwise.
Leather
Personally, I love leather. It's rich in texture, it can be worked in all kinds of ways, it's sturdy but flexible. It can be super thin or super thick. It's so versatile!
And I love that it even gets more beautiful as it ages.
I use new hides for making garments (because I need large pieces), but I also buy a lot of scraps (because I like reusing materials and because it's cheaper).
There are 2 types of leather.
Vegetable-tanned leather (not to be confused with vegan leather, which isn't real leather), is the one used for making accessories. By wetting it, you can shape it, mark it, transform it. And it hardens as it dries. So you can make fairly sturdy pieces.
Chemically-tanned leather is the one used for furniture and garments. It stays flexible and has a bit more give. That leather is used more like fabric.
Both types are awesome and worth exploring.
For LARP costumes, it's definitely a must! But for cosplay too. Leather gives your costumes a more natural, more authentic feel.
| To dig deeper into leather, I'd recommend the guide: Introduction to Leatherworking |
- Why we love it: It has character and it ages so beautifully.
- Its limits: There's a bit of a learning curve to mastering certain techniques (but I promise, it's worth it!)
Worth trying for the joy of the textures and the craftsmanship.
Faux leather
Why am I talking about both leather AND faux leather? Because, to me, they're not used for quite the same reasons.
Since the faux leather I use is pretty thin, I mostly use it for appliqué work. I love being able to use it raw edge (without finishing it), and the fact that you can find it in natural tones as well as a bunch of weirder colors, or with iridescent or metallic effects.
But if you want to make accessories with it, that works too. It just won't give quite the same look as real leather. A little trick to fake it? Double up your piece with craft foam. That'll give your faux leather more body and a more natural look.
Same thing for garments. Except instead of using EVA foam, I back my faux leather with fabric. That gives it more or less body, depending on the thickness of the fabric underneath… and I find the result more interesting than using the faux leather on its own.
- Why we love it: It comes in all kinds of colors and textures.
- Its limits: It's a lot less durable than real leather.
Worth trying for appliqué work. Or if real leather isn't an option for you (budget-wise or on principle).
Resin
I'm not an expert in mold-making and resin. But it's still worth trying. I've made a few pieces, but honestly, since I got a 3D printer, I do it less.
Careful, I'm not saying 3D printing replaces mold-making and resin. It really depends on what you're doing. If you want to make, say, 32 copies of a piece, mold-making is definitely a faster option than 3D printing, for example.
There's really a huge range of products for making molds. And a huge range of different resins. Personally, I like silicone for my molds. It's not too complicated to use, and the flexibility of the material makes demolding quick and easy. As for resin, I like the kinds that cure fairly quickly (because I'm not the most patient person…).
One last drawback: it's a potentially messy technique. And I think that's why I don't do it that much (I'm the type to get batter all over my kitchen when I cook... so imagine me with resin?).
If you want to learn more, I'd strongly suggest checking out the Sial shop (in Laval — but they also sell online).
- Why we love it: It's sturdy and allows for very clean finishes.
- Its limits: It's messy and requires proper safety precautions.
Worth trying for making multiple copies of a piece.
Cardboard
Cardboard is so underrated… Seriously, you can make cool things with it. And not just mock-ups and patterns. You can make full costumes. Yes, really.
And even if you don't want to dive into building a whole suit of armor, it's worth trying cardboard for accessories: big buttons or belt buckles, for example.
It's a material that costs next to nothing (or literally nothing if you dig through your recycling bin — like for my Vah Medoh project). It's simple to work with. And after a few coats of varnish, it holds up to the elements just as well as plenty of other materials.
- Why we love it: It costs almost nothing and it's super eco-friendly!
- Its limits: It doesn't hold up as well to impact.
Worth trying to rediscover the basics and appreciate simple materials.
There's clearly enough material for a part 2. Faux fur, Fosshape, stretch mesh, latex... the list of things I could have included here is really long.
If you want to be kept in the loop for when it comes out (and get early access to new articles, promos, and new shop items), join The Harbour. That's where everything happens first.
In the meantime, if this article made you want to try out a new material, I'd recommend taking a quick look through the crafting collection to see the guides, patterns, and templates to use with all kinds of materials!
And if you want to stay in the loop on new products, promos, and new articles to help you with your creative projects, join The Harbour!
In the meantime,
Happy sewing! Happy crafting! 🤓✂🐙