Look for Grade A for the smoothest surface with minimal "pinholes" (air bubbles). Grades B and C often use recycled content and may have more surface imperfections. 2. Choose Your Thickness
The "standard" for most costumes. It balances weight and flexibility, making it ideal for standard armor and props. High Density (65–100+ buy eva foam
/ Soft and flexible, often found in kids' craft sheets. It is prone to denting and difficult to sand smoothly but is very affordable for minor details. Look for Grade A for the smoothest surface
/ >50° Shore): The gold standard for professional armor. It is more rigid, holds crisp edges, and is a dream to sand and Dremel without "fuzzing". Choose Your Thickness The "standard" for most costumes
or Shore hardness) determines how well the foam holds its shape, sands, and takes detail. Low Density (30–60
Different project components require different depths to look "right". Common Use Case Project Example Fine details, layering, flexible trim Intricate filigree on a chestplate or bracer patterns 5mm – 8mm Versatile mid-range base armor Gauntlets, greaves, or smaller structural sections 10mm+ Substantial armor plates, weapons Heavy breastplates, sturdy shields, or sword bases 3. Where to Buy EVA Foam