How to Make Craft Foam Armor for Women


Making Craft Foam Armor For Women

Craft Foam Armor for Women

There are lots of options when you go the armor route. If you don’t want to hammer out real metal into armor, there are still a lot of other materials you can use. Some people use leather, Prince Armory arguably has the best leather working skills out there. Other options are Worbla, Craft Foam, and so many others.

This article will be about craft foam armor, and making an armored chest plate for a female!

The first thing I did was run to target and buy a super cheap white bra. You can get them anywhere. Mine was a push up, because I think push ups look better. If you’re doing a cosplay of a female with those typical video game female breasts, refer to this tutorial.

List of needed things!

  • Craft Foam
  • Bra
  • Wood Glue or Mod Podge
  • Pins
  • Hot Glue Gun
  • lots and lots of hot glue stocks

For mine I wanted a scaled/feathered look for the chest plate. I spent a good amount of time cutting out these scaled shapes, and placing them aside.

 I think I cut out about 250, making sure they were flat on the top.

Then I started hot gluing them down onto the bra.

The checkered pattern your seeing below the scales is just a weaved pattern I did with strips of craft foam. I put the bra on a large piece of foam, traced underneath it, then cut out the w shaped cups that I had just sketched. Cut that out of the foam, then folded in half to get the stomach covering. Then wove those strips on top of it like I was weaving a basket!

 Like so.

Anyways, keep gluing those feathers on. I layered them pretty close to each other. Eventually you’ll finish the top of the cup, and the last feather/scale I rounded the top of!

I then added shoulder pieces with the same techniques shown here!

Once done, you should cover the whole thing with two layers of mod podge or wood glue.

Craft foam is porous, so if you paint directly on top of it the paint will be absorbed. Putting a layer of glue avoids that!

And then you’re done! This is an unfinished picture on my mannequin, but you get the idea.

That’s it! Use a bra for a template and you’re golden.


  1. Mallory guidry
    Mallory guidryReply
    October 2, 2014 at 9:26 pm

    Hello ! Love the costume . I’m making a shredder costume from tmnt and would like to use this for the breast plate and shoulders . Do you have a better way or a picture of how it looked before you did the weaving ? Also the back of it as well. How did you peice the front and back foam together becuase I didn’t find large peices of foam . Only 12 by 18 . Will spray paint stick to modge podge as well ?

      October 2, 2014 at 9:32 pm

      Hello! I don’t have any closer photos, but it’s a basket weave! You can see something similar in step one of this tutorial here…

      The back is two strips crossing over each other, I’ll see if I can dig it out of my costume box and find it for you. If you could email I’ll have that image to you tomorrow! I think that the foam I used was 12×18! The back piece was a strip that I glued right underneath the cup and then used velcro to stick it underneath the shoulder strap. 🙂

      If you have any other questions don’t hesitate to ask!

  2. Kel
    October 13, 2014 at 10:31 pm

    Love it!! Question did you leave the whole bra intact? Or did you just use the cups? I’m making a Sgt. Calhoun costume from wreck it Ralph and am working on the chest piece.

      October 14, 2014 at 8:31 am

      I did leave the whole bra intact! It’s easier than adding a clasp eventually to the back of it. There’s enough pieces on Sgt. Calhoun that you’ll be able to cover up the straps no problem. You might even want to not cover the cups (if you get a generic cotton one) and paint resin over it. It’ll give you hard shiny cups like she has!

    • Rachel
      August 20, 2015 at 10:09 pm

      My family and I always do a themed Halloween, and this year my kids chose Wreck It Ralph. I’d totally appreciate any tips you have for Calhoun if you don’t mind. I’ve never made anything so extensive. Usually it’s me and my sewing machine.

  3. Porsha
    March 5, 2015 at 10:58 pm

    Hiya!! Just want to know if you painted over the foam and if so, what was the result? Thanks 🙂

    • Emma
      March 6, 2015 at 9:26 am

      I did paint over it! I’ll have to search for some photos and see if I can get something up. 🙂

  4. Alyssa
    April 11, 2015 at 11:06 am

    did you end up putting anything on the back? i have a mermaid cosplay this would be great for, but i dont know what to do about the back of the piece.

    • Emma
      May 1, 2015 at 2:19 pm

      I actually just used two long stripes of foam to make an X on the back. It looked good, and I was able to hide the hooks of the bra.

  5. Blair
    May 29, 2015 at 6:47 pm

    How many sheets of 12 x 18 craft foam did you need to use?

    • Emma
      June 1, 2015 at 1:06 pm


      I used about 3! Doesn’t take too much, but that’ll depend on your size.

  6. Charlotte
    June 1, 2015 at 1:04 pm

    Heya! Is this by any chance a daenerys targaryen cosplay? and would you happen to have a finished photo? this looks amazing by the way

    • Emma
      June 1, 2015 at 1:07 pm

      It’s not! Just a random one that I did, though you could definitely turn it into a targaryen cosplay! I’m still looking for a finished photo! Not sure if I ever got a photo taken of this one.

      I’ll be making another tutorial soon with Worbla, hopefully much better than this. 😉

  7. Aubrey
    August 18, 2015 at 3:26 pm


    This looks amazing! I was wondering if you used spray paint or acrylic?

    • Emma
      October 13, 2015 at 4:15 pm

      Spray paint!

  8. CompletelyCosplay
    September 15, 2015 at 3:08 pm

    That armour looks very cool and easy to make!

    CompletelyCosplay on Pinterest

    • Emma
      October 13, 2015 at 4:14 pm

      Thank you very much!

  9. Ita
    October 19, 2015 at 5:36 pm

    Thanks for the tutorial!! I’ve never worked with craft foam and your information is very useful. Your instructions should be adaptable for making this, which I really want:

    • Emma
      December 8, 2015 at 9:18 am

      That looks beautiful!! I would definitely love to see the end result if you make it!

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