EVA Foam 101 Learn the basics of EVA foam crafting in this 2-3 hour hands-on workshop

EVA Foam 101 – Notes, Tips, and Tricks

• Always work on a flat surface and keep the blade sharp to ensure your cuts are clean and accurate. Make sure to use a self healing cutting mat to avoid damaging tabletops or counters
• Make sure the contact cement is ready before trying to adhere pieces together. The surface where the cement was applied should be matte, and no longer shiny.
  • Tip: Apply a thin layer of cement and smooth it out with a piece of scrap EVA foam. Wait 5-10 min after applying the cement before attempting to adhere the pieces together.
• Use a Dremel sanding tool or sand paper and hand-sanding on your seams and edges to make them smoother for painting and finishing
• Always heat seal your foam with a heat gun before applying primer or paint – especially after sanding. This makes the foam less prone to absorbing your primer and paint and makes it smoother due to lower porosity.
• ALWAYS prime your EVA foam before painting. Prime with matte Mod Podge, PlastiDip, Flex Seal, etc.
• Spray paint is quick and easy for large areas, but latex paint is more durable and less prone to damaging the finish when bumped or dropped
• Always have proper ventilation and wear proper PPE when working with chemicals – such as contact cement or aerosol paints.
• Work outdoors as needed (i.e. if you do not have proper ventilation, when spray painting, etc.)
• If a seam is going to have a lot of tension, or if you just want to make sure it’s not going to come apart, glue it twice! Doubling up on contact cement is optional, but makes the connection between your foam pieces much stronger and ensures the entire edge got a layer of glue.
  • How do I do that…? Apply an even layer of contact cement, wait for it be ready to adhere (it should no longer be
    shiny), then apply a second layer, wait for it to be ready to adhere – then align your foam pieces and press the edges together firmly and evenly to connect them.
• If you are working with a long seam, place some wax paper between the foam pieces where you’re not working to prevent the edges from accidentally sticking together before you’re ready

Terminology

A “bevel” is an angled cut along the edge of a piece of foam – they change where the connection points are and allow for different curves and shaping when gluing foam pieces together. Bevels also increase surface area – which can create a stronger bond between 2 edges (i.e. on belts, bracelets, or headbands 

A “registration mark” is a visual indicator on EVA foam patterns that aids with assembly steps by showing where the individual pieces line up when glued together. These help to ensure a clean seam and well-aligned prop.  
Important note: Do not cut out your registration marks! They are not intended to be physically notched. Simply mark them with pen or chalk on the surface of your foam piece and cover them with paint later!