The Ultimate Guide to Primers, Coatings, and Finishing for EVA Foam, T

Hello, fellow makers! Whether you're a seasoned pro or just dipping your toes into the wonderful world of cosplay, props, and model making, one thing’s for sure: sealing and finishing your projects can make all the difference between a good build and a great one. Today, we’re diving into the nitty-gritty of primers, coatings, and finishing techniques for popular materials like EVA foam, Thibra, Fosshape, Varaform, Worbla, Foamclay, Styrene, and paper. So grab your coffee, your crafting supplies, and let’s get started!

Sealing Challenges by Material

EVA Foam

Challenges: EVA foam's porosity makes it a bit of a sponge for paint, which can lead to uneven finishes, and which can make getting a smooth, paintable surface a bit tricky. Its texture often shows through paint layers unless properly sealed. It also tends to flex, so you need a sealer that can move without cracking.

Best Sealers:

Plastidip: Great flexibility and durability, though it's on the pricier side and requires good ventilation.
Mod Podge: An affordable option that's easy to use but may require multiple coats and isn't as durable.
Flexbond: Offers excellent flexibility and durability but is also more expensive and requires several coats.

Thibra

Challenges: Thibra is a thermoplastic that can get quite smooth with heat, but it’s prone to showing fingerprints and minor imperfections. Sealing helps to create a more uniform surface.

Best Sealers:

Epsilon: Provides a very smooth, hard finish perfect for painting, but it’s expensive and takes time to cure.
Gesso: Fills in minor imperfections and creates a smooth surface but isn't flexible.

Fosshape

Challenges: Fosshape is a thermoplastic felt that becomes rigid when heated. Its fibrous texture needs a good seal to prevent paint from soaking in unevenly.

Best Sealers:

XTC-3D: Gives a very smooth, hard finish but is tricky to apply and has a long curing time.
Sandable Primer: Easier to apply and provides a good base for paint, but isn't flexible.

Varaform

Challenges: Varaform is a mesh-like thermoplastic that can be difficult to get smooth due to its texture. Proper sealing is essential for painting.

Best Sealers:

Hot Wire Foam Factory Foam Coating: Durable and designed specifically for foam, though it takes time to cure.
FloraCraft Foam: Easier to apply and provides good coverage but isn’t as durable.

Worbla

Challenges: Worbla can be bumpy and textured, especially if you’re using scraps. And it has tendency to show fingerprints. It needs a good sealer to achieve a smooth finish.

Best Sealers:

Foam Armour: Durable and flexible, making it ideal for Worbla.
Prop Monkey Studios Prime: Provides a good base for paint and is relatively easy to use.

Foamclay

Challenges: Foamclay is lightweight and sculptable, but its surface can be a bit uneven and porous.

Best Sealers:

Liquid Latex: Flexible and provides a good base for painting, though it has a strong odor.
Flexbond: Durable and flexible, perfect for foamclay, though it can be pricey.

Styrene

Sealing Challenges: Styrene is smooth and non-porous, but it can be slick, making it hard for paint to adhere without a good primer.

Best Sealers:

Sandable Primer: Provides a smooth, paintable surface.
3M Polystyrene Foam: Strong adhesion and designed for polystyrene.

Paper (and Cardboard, MDF, etc.)

Challenges: Paper is absorbent and can warp when wet. Sealing helps to prevent this and creates a better surface for painting.

Best Sealers:

Mod Podge: Seals and stiffens paper, making it easier to paint.
CosBond: Strong adhesion and prevents warping.

The Sealers: Pros and Cons

Plastidip

Pros: Flexible, durable, and provides a good base for painting.
Cons: Can be expensive, strong fumes, and requires multiple coats.

Tips for Applying PlastiDip to Your Cosplay Projects

Applying PlastiDip can be a game-changer for sealing and priming your cosplay projects, providing a smooth, flexible, and durable base for painting. Here are some tips to help you get the best results:

Clean the Surface: Ensure your foam or prop is clean and free from dust or debris. A clean surface ensures better adhesion.
Work in a Well-Ventilated Area: PlastiDip fumes can be harmful, so always work in a well-ventilated space or wear a respirator.
Use Light Coats: Apply PlastiDip in several light, even coats rather than one heavy coat. This helps to avoid drips and ensures a smooth finish. Aim for 4-5 light coats.
Maintain Consistent Distance: Hold the spray can about 6-12 inches away from the surface. This prevents the coating from becoming too thick or uneven.
Allow Adequate Drying Time: Let each coat dry for about 30 minutes before applying the next. Full curing takes about 4 hours, so be patient for the best results.
Avoid Touching Wet Coats: Resist the urge to touch or test the surface until it’s fully dry. Fingerprints can ruin the smooth finish.
Temperature Control: Apply PlastiDip in a temperature range of 60-90°F (15-32°C). Extreme temperatures can affect drying time and adhesion.

Sandable Primer

Pros: Provides a smooth, paintable surface and is easy to sand.
Cons: Can be brittle and isn’t very flexible.

Tips for Applying Sandable Primer to Your Cosplay Projects

Using sandable primer is essential for creating a smooth, professional finish on your cosplay props and costumes. Here are some tips to ensure you get the best results:

Prep the Surface: Clean your project thoroughly to remove any dust, grease, or debris. For foam and other porous materials, apply a sealer like Mod Podge first.
Shake Well: Shake the primer can vigorously for at least 2 minutes before use. This ensures the primer is well-mixed for an even application.
Use Thin Coats: Apply the primer in thin, even coats. Multiple thin layers build up a smooth surface better than one thick coat. Aim for 2-3 coats.
Maintain Distance: Hold the spray can about 10-12 inches away from the surface. This prevents the primer from pooling or running.
Drying Time: Allow each coat to dry completely before applying the next. This usually takes about 1 hour, but refer to the manufacturer’s instructions for specifics.
Sand Between Coats: Once dry, lightly sand the primer with fine-grit sandpaper (220-400 grit) to smooth out any imperfections. Wipe away dust before applying the next coat.
Work in a Ventilated Area: Use sandable primer in a well-ventilated area or wear a respirator to avoid inhaling fumes.
Temperature Control: Apply primer in a temperature range of 60-80°F (15-27°C). Extreme temperatures can affect the primer’s adhesion and drying time.

Mod Podge

Pros: Easy to use, readily available, and versatile.
Cons: Not very durable or flexible.

Tips for Applying Mod Podge to Your Cosplay Projects

Mod Podge is a versatile and easy-to-use sealer, glue, and finish that is perfect for a variety of cosplay projects. Here are some tips to help you get the best results:

Choose the Right Mod Podge: Mod Podge comes in various formulas like Matte, Gloss, and Hard Coat. Select the one that best suits your project’s finish and durability needs.
Prepare the Surface: Ensure your surface is clean and smooth. Lightly sand any rough spots on foam or other materials to ensure even application.
Use Thin, Even Coats: Apply Mod Podge in thin, even coats using a soft brush or foam applicator. Thick layers can cause streaks and take longer to dry.
Avoid Bubbles: To prevent bubbles, apply Mod Podge slowly and smooth out any bubbles with your brush or applicator while it’s still wet.
Drying Time: Allow each coat to dry thoroughly before applying the next. This usually takes about 15-20 minutes, but thicker applications might need more time.
Multiple Coats for Durability: For increased durability, especially on items that will be handled or worn, apply 2-3 coats, letting each coat dry completely.
Sand Between Coats: For an extra smooth finish, lightly sand between coats with fine-grit sandpaper (220-400 grit). Wipe away any dust before applying the next layer.
Seal with a Final Coat: Once you’ve achieved your desired coverage, apply a final coat to seal and protect your project.
Clean Tools Immediately: Clean brushes and tools with warm soapy water immediately after use to prevent Mod Podge from hardening on them.
Work in a Well-Ventilated Area: While Mod Podge is non-toxic, working in a well-ventilated area will help the drying process and keep you comfortable.

Gesso

Pros: Great for creating a paintable surface and filling in minor imperfections.
Cons: Can crack if bent or flexed too much.

Tips for Applying and Modifying Gesso for Cosplay Projects

Gesso is a fantastic primer for preparing surfaces like foam, EVA, and other materials used in cosplay. Here are some tips to ensure you get the best results:

Choose the Right Gesso: Select between white, black, or clear gesso based on your project’s needs. White is great for bright colors, black for dark themes, and clear for preserving original textures.
Prepare the Surface: Clean and lightly sand your surface to ensure better adhesion. Gesso can be applied directly to foam, EVA, and other porous materials.
Thin Coats: Apply gesso in thin, even coats with a soft brush or foam applicator. This helps prevent clumping and ensures a smooth finish.
Dilute if Needed: If gesso is too thick, you can thin it with a little water for a smoother application. This is especially useful for the first coat.
Drying Time: Allow each coat to dry completely before applying the next. This typically takes about 1 hour, but drying time may vary based on thickness and environmental conditions.
Sand Between Coats: For an ultra-smooth finish, lightly sand between coats with fine-grit sandpaper (220-400 grit). Wipe away any dust before applying the next layer.
Build Up Layers: Apply 2-3 coats for a durable, paint-ready surface. More coats may be needed for very porous or rough surfaces.
Texture Modification: For a smoother finish, add a bit of fine sand or marble dust to the gesso. For more texture, use a coarse brush or sponge during application.
Custom Colors: Mix acrylic paint into your gesso to create custom-colored primers. This can save time and paint later in the process.
Work in a Ventilated Area: Although gesso is non-toxic, working in a well-ventilated space helps with the drying process and keeps you comfortable.

Epsilon (and Episilon Pro)

This is a two-part thixotropic epoxy coating that self thickens for brushing onto a variety of surfaces without sagging and was developed for fabricators that regularly coat EPS foam.

This product is not sensitive to moisture or humidity and contains no VOC’s.

Pros: Durable and creates a very smooth finish.
Cons: Expensive and has a longer curing time.

Where Can You Find It

Reynolds Advanced Materials

Tips for Applying Epsilon in Cosplay Projects

Epsilon is a durable resin coating ideal for sealing and hardening cosplay props and armor made from foam and other materials. Here are some tips to help you achieve the best results:

Prepare the Surface: Ensure the surface is clean and free of dust or debris. For foam, consider sealing with Mod Podge or another base layer to help Epsilon adhere better.
Mix Thoroughly: Epsilon comes in two parts that need to be mixed. Follow the manufacturer’s instructions precisely and mix thoroughly to ensure proper curing.
Work Quickly: Epsilon has a limited working time once mixed, so apply it promptly to avoid it setting in the container.
Apply Thin Coats: Use a brush or foam applicator to apply thin, even coats. Multiple thin layers are better than one thick coat to prevent runs and drips.
Smooth Application: Brush out any bubbles immediately after application to ensure a smooth finish. You can use a heat gun briefly to help bubbles rise to the surface and pop.
Drying Time: Allow each coat to dry completely before applying the next. Epsilon typically takes about 24 hours to fully cure, but you can handle it carefully after 4-6 hours.
Temperature and Humidity: Apply Epsilon in a well-ventilated area with controlled temperature and humidity. Extreme conditions can affect curing and adhesion.
Sanding Between Coats: For a super smooth finish, sand lightly between coats with fine-grit sandpaper (220-400 grit). This helps to remove any imperfections.
Protective Gear: Wear gloves, a respirator, and work in a well-ventilated area. Epsilon can be irritating to the skin and harmful if inhaled.
Clean Tools Immediately: Clean brushes and tools with acetone or a similar solvent immediately after use to prevent the resin from hardening on them.

XTC-3D

XTC-3D is a protective coating for smoothing and finishing 3D printed parts. It does not melt plastic. It is a 2-part epoxy and may brushed onto 3D print, EVA, and other plastic surfaces. Coating self-levels and wets out uniformly without leaving brush strokes. Working time is 10 minutes and cure time is about 4 hours (depending on mass and temperature). The epoxy cures to a hard, impact resistant coating that can be sanded, primed and painted.

Pros: Provides a smooth, glass-like finish.
Cons: Can be difficult to work with and has a long curing time.

Where Can You Find It

Reynolds Advanced Materials

Tips for Applying XTC-3D in Cosplay Projects

XTC-3D is a popular epoxy resin coating that provides a smooth, durable finish for cosplay props and armor. Here are some tips to help you use XTC-3D effectively:

Surface Preparation: Ensure your cosplay piece is clean and free of dust and debris. Lightly sanding the surface can improve adhesion.
Mixing Ratio: XTC-3D comes in two parts that need to be mixed in equal parts by volume. Use accurate measuring tools and thoroughly mix the components.
Apply Thin Coats: Use a brush or foam applicator to apply XTC-3D in thin, even coats. Avoid applying too thickly to prevent runs and drips.
Smooth Application: Work quickly but carefully to spread the resin evenly over the surface. Use a brush to smooth out any bubbles or uneven spots.
Drying Time: XTC-3D sets quickly, so work in small sections and avoid over-brushing once applied. It cures fully in about 4-6 hours depending on temperature and humidity.
Ventilation: Use XTC-3D in a well-ventilated area or wear a respirator. The fumes can be strong, especially when mixing.
Cleanup: Clean tools and brushes immediately with acetone or isopropyl alcohol before the resin hardens.
Sand Between Coats: For a smoother finish, lightly sand between coats with fine-grit sandpaper (220-400 grit). This helps remove imperfections and rough patches.
Safety Gear: Wear gloves and protective eyewear when handling XTC-3D to protect your skin and eyes from exposure.
Experiment and Practice: Practice on small pieces or scraps to get comfortable with the application technique and timing before tackling larger projects.

FloraCraft Smooth Finish

Pros: Designed specifically for foam, easy to apply.
Cons: Not as durable as other options.

Tips for Using FloraCraft Smooth Finish in Cosplay Projects

FloraCraft Smooth Finish is an excellent product for creating a smooth, paintable surface on foam for cosplay projects. Here are some tips to help you use Smooth Finish effectively:

Surface Preparation: Ensure the foam surface is clean, dry, and free from dust and debris. Trim any excess material and sand rough edges for better adhesion.
Mixing: Stir Smooth Finish thoroughly before use to ensure a consistent texture. If the coating is too thick, you can thin it slightly with water to achieve the desired consistency.
Application Tools: Use a putty knife, spatula, or a damp sponge to apply Smooth Finish. Spread a thin layer over the foam surface, working in small sections to avoid drying before smoothing.
Layering: Apply multiple thin layers rather than one thick layer. Allow each layer to dry completely before applying the next. This helps prevent cracking and ensures a smoother finish.
Smoothing: Use a damp sponge or your fingers to smooth out the surface while the coating is still wet. This helps to eliminate brush marks and achieve an even finish.
Drying Time: Smooth Finish typically dries to the touch within 30-60 minutes. Allow it to cure fully for several hours or overnight before sanding or painting.
Sanding: Once fully dry, sand the surface with fine-grit sandpaper (220-400 grit) to achieve a smooth, even finish. Wipe away any dust before proceeding to the next step.
Painting and Detailing: Smooth Finish creates a perfect base for painting. Prime the surface with a suitable primer before applying your final paint to ensure good adhesion and coverage.
Cleanup: Clean tools and applicators with water immediately after use to prevent the Smooth Finish from hardening on them.
Storage: Store Smooth Finish in a cool, dry place with the lid tightly sealed to maintain its consistency and usability.

3M Polystyrene Foam Adhesive and Sealant

Spray on adhesives and sealants from 3M come in a variety of formulations, with the 78 being one most commonly used for polystyrene and insulation foams, like FOAMULAR and other Extruded Polystyrene (XPS) sheets.

Pros: Designed for polystyrene, strong adhesion.
Cons: Limited flexibility.

Tips for Using 3M Polystyrene Foam Sealant in Cosplay Projects

3M Polystyrene Foam Sealant is designed specifically for sealing and protecting polystyrene foam used in cosplay props and costumes. Here are some tips to help you use 3M Polystyrene Foam Sealant effectively:

Surface Preparation: Ensure the polystyrene foam surface is clean and free of dust, debris, and oils. Use a damp cloth to wipe down the surface if necessary.
Shake Well: Before use, shake the can of 3M Polystyrene Foam Sealant thoroughly to mix the contents evenly.
Test on Scrap: Always test the sealant on a small, inconspicuous area or scrap piece of polystyrene foam to ensure compatibility and desired results.
Apply Evenly: Hold the can about 6-8 inches away from the foam surface and spray in light, even coats. Avoid spraying too heavily to prevent pooling and drips.
Multiple Coats: For thorough sealing, apply 2-3 coats of 3M Polystyrene Foam Sealant, allowing each coat to dry completely before applying the next.
Ventilation: Work in a well-ventilated area or outdoors when applying 3M Polystyrene Foam Sealant to avoid inhaling fumes. Consider wearing a mask for additional protection.
Drying Time: Allow the sealant to dry completely between coats. Drying times may vary depending on temperature and humidity levels.
Cleanup: Clean the nozzle and any overspray with mineral spirits or a similar solvent immediately after use to prevent clogging.
Sandability: Once fully cured, 3M Polystyrene Foam Sealant can be sanded lightly with fine-grit sandpaper (220-400 grit) to smooth out any rough areas before painting.
Storage: Store 3M Polystyrene Foam Sealant in a cool, dry place away from direct sunlight and heat sources to prolong shelf life.

Hot Wire Foam Factory Foam Coat

Comes in 2 varieties, Exterior and All Purpose.

Exterior is weather-resistant surface for your outdoor (and indoor) foam projects. Exterior Foam Coat is not sandable. It has a rough stone feel when dry. Trowel it smooth, or brush it to make a super rough finish. This formula sets in a few hours, but takes 5 days to fully cure.

All Purpose is tough but still sandable, it sets in 30 minutes. Extend the setting time by adding up to 50% latex paint with your water before mixing it into the dry powder. Cures in 12 hours.

Pros: Specifically made for foam, very durable.
Cons: Can be pricey and takes longer to cure.

Tips for Using Hot Wire Foam Factory Foam Coat in Cosplay Projects

Hot Wire Foam Factory Foam Coat is a versatile product used to seal and strengthen foam surfaces in cosplay props and costumes. Here are some tips to help you use Foam Coating effectively:

Surface Preparation: Ensure the foam surface is clean and free of dust, debris, and oils. Lightly sanding rough areas can improve adhesion.
Mixing (if applicable): Some foam coatings may require mixing before use. Follow the manufacturer’s instructions carefully to achieve the correct consistency.
Apply Evenly: Use a brush, foam roller, or spray applicator to apply Foam Coat in thin, even coats. Start with a light coat and gradually build up layers as needed.
Smooth Application: Work quickly but carefully to spread the coating evenly over the surface. Use a brush or foam roller to smooth out any bubbles or uneven spots.
Drying Time: Allow each coat to dry completely before applying the next. Drying times may vary depending on temperature and humidity levels.
Ventilation: Use Foam Coating in a well-ventilated area or outdoors to avoid inhaling fumes. Consider wearing a mask for additional protection.
Cleanup: Clean tools and brushes immediately with soap and water or the recommended solvent to prevent the coating from hardening on them.
Sandability: Once fully cured, Foam Coating can be sanded lightly with fine-grit sandpaper (220-400 grit) to smooth out imperfections before painting.
Storage: Store Foam Coating in a cool, dry place away from direct sunlight and heat sources to maintain its effectiveness.
Practice and Experiment: Practice on scrap pieces of foam to get comfortable with the application technique and timing before applying to your main cosplay project.

DELUXE MATERIALS - Foam Armour Wood and Foam Protective Coating

Designed originally for radio controlled airplanes and gliders, the coating is a water based resin. The manufacturer also produces fillers, adhesives, and protectorants.

Pros: Flexible and durable.
Cons: Expensive and requires multiple coats.

Tips for Using Deluxe Materials Foam Armour Wood and Foam Protective Coating in Cosplay Projects

Deluxe Materials Foam Armour Wood and Foam Protective Coating is designed to provide a durable and protective finish for foam and wood surfaces used in cosplay props and costumes. Here are some tips to help you use this product effectively:

Surface Preparation: Ensure the foam or wood surface is clean, dry, and free from dust and debris before applying Foam Armour. Sand rough areas lightly for a smoother finish.
Application Method: Use a brush, foam roller, or spray applicator to apply Foam Armour in thin, even coats. Start with a light coat and gradually build up layers as needed for optimal protection.
Even Coverage: Ensure you apply the coating evenly across the entire surface to avoid streaks or patches. Pay special attention to edges and intricate details.
Drying Time: Allow each coat to dry completely according to the manufacturer's instructions before applying additional coats or proceeding with painting.
Ventilation: Work in a well-ventilated area or outdoors when applying Foam Armour to avoid inhaling fumes. Consider wearing a mask for additional protection.
Cleanup: Clean tools and brushes immediately with soap and water or the recommended solvent to prevent the coating from hardening on them.
Sandability: Once fully cured, Foam Armour can be sanded lightly with fine-grit sandpaper (220-400 grit) to smooth out imperfections before painting or applying additional layers.
Storage: Store Foam Armour in a cool, dry place away from direct sunlight and heat sources to maintain its effectiveness.

Liquid Latex

Pros: Flexible and provides a good surface for painting.
Cons: Strong odor and can be tricky to apply evenly. Lots of brand to choose, may have to test for best quality and consistency.

Tips for Using Liquid Latex in Cosplay Projects

Liquid latex is a versatile material commonly used in cosplay for creating textures, molds, and coatings. Here are some tips to help you use liquid latex effectively:

Surface Preparation: Ensure the surface is clean, dry, and free from dust and debris before applying liquid latex. Use a brush to remove any loose particles.
Application Tools: Use a disposable foam brush, a soft bristle brush, or a sponge to apply liquid latex evenly. Avoid using expensive brushes, as latex can be challenging to clean off completely.
Thin Layers: Apply liquid latex in thin layers to build up the desired thickness. Allow each layer to dry completely before adding the next. A hairdryer on a low setting can speed up drying time.
Curing Time: Liquid latex dries relatively quickly, but curing time can vary based on humidity and layer thickness. Ensure each layer is fully dry and opaque before proceeding.
Reinforcement: For larger or more complex pieces, consider adding a fabric or cheesecloth backing between layers of latex to increase durability and strength.
Texture and Detail: Liquid latex can be manipulated with tools or textured with sponges, brushes, or even your fingertips while wet to create unique textures and effects.
Painting and Coloring: Once fully cured, liquid latex can be painted with acrylic paints or latex-based paints. Use powder or baby powder to reduce stickiness before painting.
Storage: Store liquid latex in a cool, dark place with the lid tightly sealed to prevent drying out. Avoid exposure to direct sunlight and extreme temperatures.
Cleanup: Clean brushes and tools with soap and water immediately after use. Latex can dry quickly and become challenging to remove once cured.
Safety: Work in a well-ventilated area when using liquid latex. Some individuals may have latex allergies, so wear gloves if you have sensitive skin.

Flex Seal

Like Plastidip, this sealant ad coating comes in a variety of forms, including liquid, paste, spray, and even tape.

Pros: Durable and waterproof.
Cons: Can be messy and difficult to control. More expensive than similar sealants.

Tips for Using Flex Seal in Cosplay Projects

Flex Seal is a popular sealant and coating that offers flexibility and durability for cosplay props and costumes. Here are some tips to help you use Flex Seal effectively:

Surface Preparation: Ensure the surface is clean, dry, and free from dust and debris before applying Flex Seal. Use a cloth or brush to remove any loose particles.
Shake Well: Before use, shake the can of Flex Seal thoroughly to mix the contents and ensure even application.
Spray Application: Apply Flex Seal in thin, even coats. Hold the can about 8-12 inches away from the surface and spray in a sweeping motion to avoid drips or pooling.
Multiple Coats: For best results, apply 2-3 coats of Flex Seal, allowing each coat to dry completely before applying the next. This helps build up a strong, flexible barrier.
Drying Time: Flex Seal dries to the touch within 2-3 hours, but full curing can take up to 24-48 hours depending on temperature and humidity. Allow sufficient drying time between coats.
Ventilation: Work in a well-ventilated area or outdoors when using Flex Seal to avoid inhaling fumes. Consider wearing a mask for additional protection.
Cleanup: Clean the nozzle and any overspray with mineral spirits or a similar solvent immediately after use to prevent clogging.
Painting and Coloring: Once fully cured, Flex Seal can be painted with acrylic paints or spray paints designed for flexible surfaces. Ensure the paint is compatible with Flex Seal for best adhesion.
Storage: Store Flex Seal in a cool, dry place away from direct sunlight and heat sources. Keep the lid tightly sealed to prevent drying out.
Safety: Follow all safety instructions on the product label. Flex Seal is flammable when wet, so avoid open flames or sparks during application and drying.

Prop Monkey Studios Fine Finish

Fine Finish adds a strong, sandable and wet-sandable surface to EVA foam. It's a nontoxic, VOC free, brush-on, acrylic-based filler and contains very fine-sized particles for professional results. Use it as a final set of coats to develop metallic like looks.

Pros: Provides a very smooth finish and is easy to sand.
Cons: Can be expensive and requires proper ventilation.

Where Can You Find It

PropMonkey Studio

Tips for Using Prop Monkey Studios Fine Finish in Cosplay Projects

Prop Monkey Studios Fine Finish is a specialized coating designed to provide a smooth and durable finish for cosplay props and costumes. Here are some tips to help you use Fine Finish effectively:

Surface Preparation: Ensure the surface is clean, dry, and free from dust and debris before applying Fine Finish. Smooth any rough areas with sandpaper for a polished result.
Shake Well: Before use, shake the jar of Fine Finish thoroughly to mix the contents and ensure an even application.
Spray Application: Apply Fine Finish in light, even coats. Use a soft, fine-hair brush, using gentle strokes to avoid drips or runs. Apply multiple coats as needed for coverage.
Drying Time: Fine Finish dries to the touch within minutes, but allow each coat to dry completely before applying the next. Full curing typically takes 24 hours, depending on humidity and temperature.
Sandability: Once fully cured, Fine Finish can be lightly sanded with fine-grit sandpaper (220-400 grit) to smooth out imperfections and prepare for painting or additional layers.
Ventilation: Work in a well-ventilated area or outdoors when using Fine Finish to avoid inhaling fumes. Consider wearing a mask for additional protection.
Cleanup: Clean brush with soap & water or rubbing alcohol immediately after use to prevent clogging and ensure the brush remains usable.
Painting and Detailing: Fine Finish provides a smooth base for painting with acrylic paints or other finishes. Ensure the surface is clean and dry before applying paint.
Storage: Store Fine Finish in a cool, dry place away from direct sunlight and heat sources to maintain its quality and effectiveness.
Experimentation: Test Fine Finish on a small, inconspicuous area or scrap piece of material before applying to your main cosplay project to ensure compatibility and desired results.

Prop Monkey Studios Prime

Is a first coat primer for EVA foam. It is a non-toxic, VOC free, flexible, extra-fine pore filler and adhesion enhancer. It applies easily and dries quickly.

Pros: Good for priming various materials and provides a nice base for paint.
Cons: Not as flexible as some other options.

Where Can You Find It

PropMonkey Studio

Tips for Using Prop Monkey Studios Prime in Cosplay Projects

Prop Monkey Studios Prime is a specialized primer designed to prepare surfaces for painting in cosplay projects, ensuring a smooth and durable base. Here are some tips to help you use Prime effectively:

Surface Preparation: Ensure the surface is clean, dry, and free from dust and debris before applying Prime. Smooth any rough areas with sandpaper for optimal adhesion.
Shake Well: Before use, shake the can of Prime thoroughly to mix the contents and ensure an even application.
Spray Application: Apply Prime in light, even coats. Use soft flat acrylic brush, and after firmly applying product, smooth out filler with light brush strokes. Apply multiple coats as needed for coverage.
Drying Time: Prime dries quickly to the touch within minutes, but allow each coat to dry completely before applying the next. Full curing typically takes 24 hours, depending on humidity and temperature.
Sandability: Once fully cured, Prime can be lightly sanded with fine-grit sandpaper (220-400 grit) to smooth out imperfections and prepare for painting or additional layers.
Ventilation: Work in a well-ventilated area or outdoors when using Prime to avoid inhaling fumes. Consider wearing a mask for additional protection.
Cleanup: Clean brush with soap and water. Warning: Do not store upside down and keep rim clean. Lid may stick to jar).
Painting and Detailing: Prime provides a smooth base for painting with acrylic paints or other finishes. Ensure the surface is clean and dry before applying paint.
Storage: Store Prime in a cool, dry place away from direct sunlight and heat sources to maintain its quality and effectiveness.
Experimentation: Test Prime on a small, inconspicuous area or scrap piece of material before applying to your main cosplay project to ensure compatibility and desired results.

Prop Monkey Studios Gap Filla

This is an easy-to-apply, non-toxic, sandable/wet sandable, flexible professional gap filler for EVA foam. Designed to fill in cracks, gaps, and seams, and also to build up edges, transitions, and shapes. It can also be used as a primer, but will not create as fine a surface as other Prop Monkey products.

Pros: Great for filling gaps and creating a smooth surface.
Cons: Needs to be sanded after application.

Where Can You Find It

PropMonkey Studio

Tips for Using Prop Monkey Studios Gap Filla in Cosplay Projects

Prop Monkey Studios Gap Filla is designed to fill gaps and seams in cosplay props and costumes, providing a smooth finish for painting and detailing. Here are some tips to help you use Gap Filla effectively:

Surface Preparation: Ensure the surfaces to be filled are clean, dry, and free from dust and debris. Sand rough edges or surfaces lightly to create a better bonding surface.
Application Tools: Use a putty knife, spatula, or applicator tool to apply Gap Filla into the gaps or seams. Work in small sections to ensure thorough coverage and avoid over-application.
Smoothing and Shaping: Smooth the Gap Filla with a wet finger or damp cloth to blend it into the surrounding surface. Shape and contour as needed to match the desired shape of your prop or costume piece.
Drying Time: Allow Gap Filla to dry completely according to the manufacturer's instructions. This may take several hours, depending on the thickness of the application and environmental conditions.
Sanding: Once fully cured, sand the filled areas with fine-grit sandpaper (220-400 grit) to achieve a smooth finish. Feather the edges to blend seamlessly with the rest of the surface.
Painting and Finishing: Gap Filla can be painted over once fully cured. Prime the filled areas before painting to ensure even coverage and adhesion of paint.
Cleanup: Clean tools and applicators with water immediately after use to prevent the Gap Filla from hardening on them.
Storage: Store Gap Filla in a cool, dry place with the lid tightly sealed to maintain its usability.

CosBond

CosBond products include sheet double-sided adhesives and sheet reinforcers for strap bonding and strengthening high use points in cosplay. The double-sided adhesives can also be used as a surface for surface for paint and other colorants.

Pros: Strong adhesion and easy to use. Generally flexible in use.
Cons: Can have low flexibly in some uses, which can be an issue for certain projects.

Tips for Using CosBond in Cosplay Projects

CosBond is a versatile adhesive and reinforcement product that is commonly used in cosplay for bonding, reinforcing, and sealing foam and other materials. Here are some tips to help you use CosBond effectively:

Surface Preparation: Ensure the surfaces to be bonded are clean, dry, and free from dust and debris. Smooth any rough areas with sandpaper for better adhesion.
Cutting and Application: CosBond comes in sheets or rolls with adhesive on one or both sides. Cut the CosBond to the desired shape and size before peeling off the backing and applying it to the surface. Use scissors or a craft knife for precise cuts.
Bonding: Press the CosBond firmly onto the surface, applying even pressure to ensure a strong bond. Use a roller or flat object to smooth out any air bubbles or wrinkles.
Activation: To activate the adhesive, apply heat using a heat gun or hairdryer. Heat the CosBond evenly until you see it become glossy and slightly transparent, indicating that the adhesive has activated and bonded securely.
Sealing Edges: Seal the edges of the CosBond with additional heat or a small amount of super glue for extra durability and to prevent peeling.
Reinforcement: Use CosBond to reinforce joints, seams, and areas that undergo stress or movement in your cosplay props and costumes.
Painting and Detailing: CosBond can be painted over once applied and activated. Prime the surface before painting to ensure even coverage and adhesion of paint.
Cleanup: Clean tools and surfaces with rubbing alcohol or a similar solvent to remove any adhesive residue.
Storage: Store CosBond in a cool, dry place with the backing paper intact to maintain its adhesive properties.

Rosco Flexbond

Not to be confused with the popular mortar or archery adhesive, this adhesive is specifically glue and primer formulated for cosplay. It is water based and resists cracking, peeling, and flaking.

Pros: Flexible and durable, great for foam.
Cons: Can be expensive and requires multiple coats.

Tips for Using Flexbond in Cosplay Projects

Flexbond is a popular sealant and adhesive used in cosplay for strengthening, sealing, and priming foam and other materials. Here are some tips to help you use Flexbond effectively:

Surface Preparation: Ensure the surface is clean, dry, and free from dust and debris before applying Flexbond. Smooth any rough areas with sandpaper for better adhesion.
Application Tools: Use a disposable foam brush, paintbrush, or sponge to apply Flexbond evenly. Start with thin layers and build up as needed for desired coverage.
Thinning: Flexbond can be thinned with water for easier application and to achieve different levels of thickness. Experiment with the ratio of water to Flexbond to find the consistency that works best for your project.
Drying Time: Flexbond dries to the touch within 30-60 minutes, depending on environmental conditions. Allow each layer to dry completely before applying additional coats or moving on to the next step.
Flexibility: Flexbond remains flexible when dry, making it ideal for applications on flexible materials like foam. It helps maintain the shape and flexibility of your cosplay props and costumes.
Sandability: Once fully cured, Flexbond can be sanded with fine-grit sandpaper (220-400 grit) to smooth out imperfections and prepare for painting or detailing.
Painting and Detailing: Flexbond provides a smooth base for painting with acrylic paints or other finishes. Prime the surface before painting to ensure even coverage and adhesion of paint.
Cleanup: Clean tools and brushes with water immediately after use to prevent Flexbond from hardening on them.
Storage: Store Flexbond in a cool, dry place with the lid tightly sealed to maintain its usability.

Tips for Different Skill Levels

Beginners

Tip: Start with easy-to-use sealers like Mod Podge or Gesso. They’re inexpensive and provide a decent finish with minimal effort. Practice applying even coats and sanding between layers for a smoother finish.

Mod Podge on EVA Foam: Apply in thin, even layers with a brush, allowing each coat to dry before adding the next. Sand lightly between coats for a smoother finish.
Gesso on Thibra: Use a foam brush to apply Gesso in thin layers. Sand between coats to achieve a smooth surface.

Intermediate

Tip: Experiment with more advanced sealers like Plastidip or Epsilon. These will provide better durability and a smoother surface but require more technique and care. Always work in a well-ventilated area and use protective gear.

Plastidip on EVA Foam: Spray in light, even coats in a well-ventilated area. Let each coat dry fully before applying the next to avoid drips.
Epsilon on Thibra: Mix Epsilon thoroughly and apply with a brush. Work in a well-ventilated area and wear gloves. Allow plenty of time for each layer to cure fully.

Advanced

Tip: Combine different sealers for the best results. For example, use Gesso to fill in larger imperfections, then follow up with Plastidip for a durable, flexible finish. Don't be afraid to experiment with new products and techniques to achieve the perfect finish for your project.

Combining Sealers: Use Gesso to fill in large imperfections on Worbla, then follow up with Plastidip for a flexible, durable finish. This approach combines the best properties of each sealer.
Using XTC-3D on Fosshape: Mix and apply carefully, ensuring you have a smooth, even coat. This can be tricky, but it results in an incredibly smooth surface for painting.

Quick Look at Materials and Recommended Sealers

*Material*	Sealer	Ease of Application	Durability	Flexibility	Painting/Coloring	Cost	Applications Needed	Curing Time
EVA Foam	Plastidip	Medium	High	High	Good	High	2-3	4 hours
	Mod Podge	Easy	Low	Medium	Medium	Low	2-4	1 hour
Thibra	Epsilon	Medium	High	Medium	Excellent	High	2	24 hours
	Gesso	Easy	Medium	Low	Good	Low	2-3	2 hours
Fosshape	XTC-3D	Hard	High	Low	Excellent	High	1-2	24 hours
	Sandable Primer	Easy	Medium	Low	Good	Medium	2-3	1 hour
Varaform	Hot Wire Foam Factory Coating	Medium	High	Medium	Good	High	2-3	4 hours
	FloraCraft Foam	Easy	Medium	Medium	Good	Medium	2-3	1-2 hours
Worbla	Foam Armour	Medium	High	High	Good	High	2-3	4-6 hours
	Prop Monkey Studios Prime	Medium	High	Medium	Good	High	2-3	2-3 hours
Foamclay	Liquid Latex	Medium	High	High	Good	Medium	2-3	1-2 hours
	Flexbond	Medium	High	High	Good	High	2-3	4 hours
Styrene	Sandable Primer	Easy	Medium	Low	Good	Medium	2-3	1 hour
	3M Polystyrene Foam	Medium	High	Low	Good	High	1-2	1-2 hours
Paper	Mod Podge	Easy	Low	Medium	Medium	Low	2-4	1 hour
	CosBond	Easy	High	Low	Good	Medium	1-2	1-2 hours