When it comes to the overall versatility of foam, the possibilities are endless. While most people think of foam as a couch cushion or house insulation, it can be used in a variety of craft projects as well, including DIY cosplay. If you are a fan of cosplay, then you know that foam is often used to create weapons that complete your character. Whether you are a valiant knight or the cruelest villain, a sword can lend authenticity to your look while giving the character an added edge. Let’s take a look at how to make a cosplay sword using foam.
Why Use Foam for Cosplay Swords?
When choosing the materials, there are plenty of options on the market you can use. While you could use cardboard or poster board, those options have their drawbacks. For instance, the sword may be flimsy, easy to damage, and flat in appearance. You could opt for wood for your sword, as some cosplayers do, but this option can be heavy, costly, and difficult to work with. Foam is the best choice for a cosplay sword for a few reasons. For one, foam isn’t as heavy as wood, so it doesn’t add as much weight to your hand. Foam is also easier to work with for experienced and novice cosplayers alike. Best of all, foam is an affordable solution! If you make mistakes, it won’t be as expensive as if you’re working with wood.
What Type of Foam Works Well For a Cosplay Sword?
When it comes to making a DIY cosplay sword, the type of foam is the first thing to consider. While there are a lot of different foam types available, not all of them are well-suited for making cosplay swords. There are two types of foam that are ideal for cosplay swords:
- Cross-Linked Polyethylene – Cross-linked polyethylene foam (XLPE) is available in a wide range of colors, so it’s great if you want to create a sword with a specific color for your character. It also offers a smoother feel than some other foams do. It offers more weight for those looking for a heavier feel, and it also offers great shock absorbency if you are looking to engage in swordplay.
- Polyethylene Foam Sheets 2.2LB – Polyethylene Foam Sheets are also a popular choice. These sheets are exceptionally strong material thanks to closed cell polyethylene foam. This makes the foam tougher and longer lasting than open-celled foam solutions while making it more resistant to rips, tears, stains, or grease. This foam is ideal for a range of applications, including cosplay.
How to Make A Cosplay Sword
To start, pull together the appropriate materials. You will need your chosen foam type, but also items such as a dremel, tracing paper, a sharp knife, a pipe or conduit for the handle, a ruler, and paint in metallic colors (if you want to paint your sword). You will also need adhesive, and it is important to choose the right glue for the job.
Once you have gathered all the necessary supplies, trace your sword outline onto the tracing paper. Most cosplayers are portraying specific characters, so the sword design may be something you already know. You may even be able to download a template of the exact sword of the character to make things easier. Trace the paper outline onto the foam with a marker, later you will want to make your initial cut along the line for accuracy. Outline two separate swords to get a multi-dimensional look instead of a flat piece.
First, you will use a dremel to carve a channel into the two foam parts for the PVC. Make sure you measure how long the sword is before you begin. The dremel can also be used to shape the foam to the 3D sword shape. The second round of cutting will separate the two sword pieces from the rest of the foam.
If you decide to put the sword together in parts, you will want to paint the parts first. Doing this will ensure the colors of the blade don’t get on the handle and vice versa. There are metallic silver paints you can use to make the blade look like real metal, but the handle can be painted a color that is more appropriate for the character you are portraying.
Once the foam cutouts have completely dried, you can assemble and finalize the sword. Use the PVC pipe as the base to make the handle more sturdy. Your PVC should run from the bottom of the handle to approximately 5 inches from the tip of the blade. Marking these measurements will help you properly line up your pieces and show you where to put the adhesive.
Once you have the measurements and marks in place, you can use your adhesive to connect the pieces over the PVC pipe. Once you glue your blade and handle cutouts, let it sit for a few hours to allow the glue to fully dry. You should now have a three-dimensional sword that is perfect for your next cosplay event!
Enjoy Your Next Cosplay Event with a DIY Foam Sword
We hope this post has helped you gain the confidence you need to create your own DIY cosplay sword for your next event. Just follow these simple instructions, and you’ll have a great prop that can be reused for multiple different occasions. To learn how to make a wider variety of equipment, check out our post on how to build your own LARP equipment with custom foam. We walk you through using foam to make weaponry and enhance your costume!
