MATERIAL TALK

Flexible Foams & Creative Materials

This category explores materials that offer flexibility, resilience, or unique heat-forming properties, making them ideal for dynamic models, intricate costume elements, props, and detailed work where pliability is key.

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Quick Reference: Flexible Foams & Creative Materials

Use this quick guide to understand the primary characteristics and common uses of flexible foams and other creative materials in model making.

Material	Key Characteristics	Common Model Making Uses
EVA Foam	Flexible, resilient, closed-cell, durable, easy to cut & heat-form.	Cosplay armour/props, flexible model components, cushioning, textured areas.
Plastazote	High-quality polyethylene foam, pure, resilient, consistent closed-cell structure, non-toxic.	Precision prop making, prosthetics, packaging, lightweight flexible structures.
Worbla	Thermoplastic sheet (not a foam), mouldable when heated, rigid when cool, self-adhesive, durable.	Cosplay, intricate props, sculpture, highly detailed custom components.
Cellular Rubber Mat	Flexible, resilient rubber-based foam, closed-cell, highly compressible, grippy.	Anti-slip bases, vibration dampening, flexible seals, miniature tyres, terrain texture.

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EVA Foam (Ethylene-Vinyl Acetate)

EVA foam is a versatile, closed-cell foam known for its excellent flexibility, resilience, and durability. It's a popular choice for a wide range of creative and model-making applications due to its easy workability and soft, non-toxic nature.

Characteristics:

Material: Ethylene-vinyl acetate polymer.
Texture & Consistency: Smooth, spongy, and resilient. Available in various densities, affecting its firmness and flexibility.
Durability & Resistance: Durable, water-resistant, and absorbs impact well. It doesn't easily crumble.
Workability: Easy to cut with a craft knife or scissors. Can be shaped using heat (e.g., heat gun) and retains its new form once cooled. Adheres well with contact adhesive, hot glue, or superglue. Takes paint well, especially when primed.

Uses & Applications:

Widely used in cosplay for armour and props, theatrical set design, industrial models requiring flexible components, and general crafting.
Excellent for creating curved surfaces, textured areas, and flexible joints in models.

Specific Types of EVA Foam:

EVA CF65 Craft Foam: The 'CF65' typically indicates a higher density or firmness. This type is preferred when more structural integrity or a harder surface is needed for components that still require some flexibility, such as costume armour or complex prop designs.
EVA Low Density Craft Foam: This refers to a softer, more pliable version of EVA foam. It's ideal for cushioning, padding, general crafting, and forms where a high degree of flexibility and compression is desired.

Sourcing:

Commonly available in sheets of various thicknesses, colours, and densities.

Plastazote

Plastazote is a high-quality, closed-cell, cross-linked polyethylene foam known for its purity, excellent resilience, and consistent cell structure. While it feels flexible, it's also very durable and holds its shape well.

Characteristics:

Material: Cross-linked polyethylene (LDPE).
Texture & Consistency: Smooth, clean, and consistent closed-cell structure. It's lightweight, non-toxic, and hypoallergenic.
Durability & Resistance: Highly durable, resistant to chemicals, moisture, and extreme temperatures. Excellent shock absorption.
Workability: Can be cut cleanly, heat-formed, and glued. It's often chosen for precision applications where a clean, non-shedding foam is required.

Uses & Applications:

Frequently used in prop making, cosplay, prosthetics, packaging for delicate items, and medical applications due to its inert properties.
In model making, it can be used for cushioning, creating lightweight structural components that require some give, or for intricate cut-out designs.

Sourcing:

Available in a range of densities, colours, and sheet sizes.

Worbla

Worbla is a brand of thermoplastic sheet material, distinct from traditional foams. It becomes highly pliable and mouldable when heated, and then hardens to a rigid, durable form once cooled, making it uniquely versatile for complex shapes.

Characteristics:

Material: Thermoplastic sheet (not a foam). It's a non-toxic, non-plastic, composite material often made from wood pulp and plastics.
Texture & Consistency: Solid sheet that becomes soft and flexible when heated (e.g., with a heat gun or hot water). It has a slight texture and is self-adhesive when hot.
Workability: Can be easily shaped by hand when warm, cut with scissors or a knife, and layered. Scraps can be re-heated and blended, minimising waste. It can be sanded, primed, and painted for a smooth finish.
Finish: It dries to a rigid and durable finish.

Uses & Applications:

Extremely popular in cosplay, prop making, jewellery, sculpture, and creating highly detailed and custom components for models that require intricate shaping and durability.
Ideal for armour, weapons, masks, or complex organic shapes that need to hold their form rigidly after creation.

Sourcing:

Sold in sheets and various specialised forms (e.g., Worbla's Finest Art, Black Art, Mesh Art).

Cellular Rubber Mat

A cellular rubber mat is a flexible, resilient material with a closed-cell foam structure, offering properties more akin to rubber than rigid plastics. It's highly compressible and regains its shape well.

Characteristics:

Material: Rubber-based elastomeric foam.
Texture & Consistency: Soft, flexible, and spongy with a uniform closed-cell structure. It has a slightly grippy, rubbery feel.
Durability & Resistance: Excellent cushioning, shock absorption, and sound-dampening properties. Resistant to moisture and some chemicals.
Workability: Can be cut with scissors or a sharp knife. Adheres well with appropriate rubber or contact adhesives.

Uses & Applications:

Used in model making for anti-slip bases, vibration dampening, creating flexible seals, padding, or as a material for miniature tyres or flexible components that require a rubber-like texture.
Useful for creating realistic ground textures for dioramas where some give or bounce is desired.

Sourcing: