If you know the right materials, any project is possible!

Let’s face it: costumes are rarely simple. More often than not, a character’s wardrobe usually consists of abnormally shaped garments, crazy armor, and physics-defying hair. Everyone knows that the key to a successful cosplay is accuracy, but how can the average costumer outside of Hollywood ever hope to reproduce pieces you can’t just walk into your local store to buy? The key is the materials!

There is a wide variety of materials easily available to the average cosplayer. Used properly, they can make all the difference in your costume. A walk through your local craft store with an open mind can offer a wealth of potential possibilities that can solve your most challenging project. There are some particular materials that have become “cosplay staples” and whether you’re new to the art of cosplay or not, becoming aware of these products can take you to the next level.

I have compiled a list of some of the most popular materials used by cosplayers for both costume, prop, and wig construction. Always test these products before you apply it to a finished project and read all directions and cautions prior to use.

Duct Tape

It really DOES hold the universe together, seams included!

It really does hold the universe together! Perhaps the #1 most used cosplay material next to fabric, duct tape is a miracle product. Not only does it provide a firm adhesive, but it can be used for reinforcement and even be used to create the entire costume itself! Duct tape can be used to make armor, weapons, or even trims to clothes and shoes. Every cosplayer should have a roll on them at all times, particularly with an “emergency repair kit”. Accidents and malfunctions happen all the time at conventions, and duct tape is a perfect quick fix. One of the downsides to duct tape is that it can be difficult to remove cleanly. While strong, I wouldn’t recommend it for use on anything where there are concentrated areas of stress. Most of the time, duct tape shouldn’t be used for a permanent bond.

No longer limited to steel-gray, duct tape comes in a variety of colors. You can also paint it and apply other types of materials over it, like gesso, clay, and other hardening products.

FABRI-TAC (http://www.beaconcreates.com/cgfab.html)

You may never want to use a glue gun again!

A lot of costumes feature elaborate details and tight corners that make it hard to finish cleanly with a sewing machine. Sometimes you need to do a hem without a stitch. For those familiar with the “glory that is” Fabri-tac, this will be one glue you will not want to be without in your sewing kit. Some cosplayers have even made entire costumes using exclusively Fabri-tac and testify that it’s “better than a hot glue gun”. It’s available at all major craft and fabric stores and is reasonably priced for a large bottle. Like with all adhesives, though, take care: “Make sure you plan out where exactly you want to place the material/item and how it will form and work. You want to plan because that glue dries quickly and one little mess up will make it look a little lop-sided,” says Alexandra “Bellavoce4″ Caragiulo. Her Kingdom Hearts II Larxene wig required Fabri-tac to extend the “antennae” using parts of another wig. The result is seamless.

Fun Foam

Penwiper's fun foam armor tutorial proves it can yield stunning results.

“Fun foam” or generally named craft foam is a fantastic and versatile material that can solve all sorts of outrageous costume elements. From armor to wings, hats to shoes, with some effort and skill, fun foam is a quick, cheap, and easy solution. Found at any craft store, it comes in sheets both sold singly and in packages cut to different dimensions usually about 1/16 of an inch thick. It is now available in yards as well. While it comes in a variety of different colors, you can paint it (just be sure to prime first otherwise the paint may crack). Personally, I’ve made several costume pieces using fun foam, including shoulder armor and shoes. You can sew fun foam to fabric, and it can be molded to any shape using a combination of glue and heat. One of the most popular tutorials in making armor uses fun foam, found here.

Like any other material, it has its limitations. Fun foam should not be used in areas that are high-stress and likely to encounter repeated impacts. Therefore, expect to replace any costume pieces made with it after a few uses. Single sheets sell for about fifty cents a piece, while packages run around a few dollars.

Sculpey (http://www.sculpey.com)

Another cosplay construction marvel is Sculpey polymer clay. Primarily used in prop and accessory work, Sculpey is used to create a lot of intricate and unusual parts really easily. It’s widely available at any local craft store and runs from a few dollars for single two ounce packages to large variety and bulk packs. There are also a handful of different types of Sculpey, which can be found listed on their website. No kiln required, just put it in your conventional oven at 275 degrees Fahrenheit and bake 15 minutes for every quarter inch of thickness. It can be sanded, painted, and some of their latest products can even be carved. Be sure, however, to follow all instructions on the packaging.

Super Sculpey is the best the company offers.

Most recommended for cosplay is their Super Sculpey, which is their highest quality polymer clay. Used by professionals in a variety of creative industries, cosplayers find it offers the best results than any other product offered by the company. This is usually the best solution for unusual jewelery, costume adornments, and elaborate props. The website offers a lot of valuable tips, techniques, and tutorials that can be adapted to any need.

Paperclay (http://www.paperclay.com)

Similar to Sculpey, Paperclay offers all the same benefits and more. It requires no baking and air dries, making it very useful for projects that aren’t able to go into an oven. This material is more lightweight, making it useful for props and large accessories, however this also means it’s not as strong as its polymer clay cousin.

Britt used Paperclay for most of the detail work on her headdress and keyblade. Photo by AC Paradise.

“Paperclay is also easy. It is easily shaped with water and can be sanded smooth after it dries. It does crack after it dries, but this is easily fixed with wet paperclay,” says Britt (cosplay.com user “makeshiftwings”).

While it may not be as strong, Paperclay is still remarkably durable. Britt offers some tips on how to handle it: “Use lots of water when working with paperclay. Fill in cracks with paperclay dipped completely in water. Sand once, fill in any dents, and sand again. Keep repeating until smooth. Great for details that need to be light; better than Sculpey because it can be sanded [more smoothly] and is lighter, but isn’t as strong. My swords have survived 3 cons without any damage, though. Can be painted without priming with acrylics. Cover with an acrylic sealant spray.”

Also reasonably priced and most commonly found at Michael’s craft stores, it is recommended you purchase instead in bulk directly from the website. “If you order in bulk off of [the website], it’s half priced! Plus, if you order it this way, you’ll have a ton in hand. Very useful to have if you cosplay a lot,” says Britt.

Crayola Model Magic (http://www.crayola.com/products/splash/MODEL_MAGIC/index.cfm)

Another molding medium that is easy to obtain and affordable is Crayola’s Model Magic. Sold in packages ranging from 2.5 oz singles to 2 pound buckets, Model Magic requires even less preparation than more professional products. Like Paperclay, it air-dries within 24 hours and can be painted. There are more limitations, however. Model Magic is not as yielding before dried, making intricate details difficult to obtain. It dries to the consistency of dense foam, becoming flexible and lightweight though not nearly as strong as Paperclay or Sculpey.

Details to the staffs and the gold headband were made using Model Magic.

I would recommend Model Magic for simple three-dimensional details that won’t encounter much stress. I’ve used it on large props to economically solve molding work, such as rings and prongs. Other uses, like jewelery and headbands, may need repair after a short period of time due to cracking. Left unresolved, the medium can easily break apart, making repair impossible.

Got2b Glued Styling Spiking Glue

Bellavoce4'S Larxene wig used Got2b Glued to keep her signature spikes in place. Photo by Bellavoce4 at DeviantART.

Styling wigs is perhaps one the most challenging aspects of cosplay, and styled wigs can really add a significant cost to project. One thing about a lot of anime/manga and video game characters is that they often possess gravity-defying impossible spikes. Achieving these spikes on your own can be extremely difficult. Fortunately, there are some products out there that can make the job a lot easier and the result worth the effort. Got2b Glued stying spiking glue comes highly recommended to get the most difficult spikes to stay put. Reviews are mixed, however, for real hair as far as the lasting effects long-term use can cause. If you plan to dress as other characters during your convention, only use this product finished on a styled wig. A large bottle runs around $5.

These are only a few of a wealth of materials used by a lot of experienced cosplayers. It goes without saying that you should always read directions and cautions carefully before use. Regardless if you’re experienced or not, you should also test your pieces for durability prior to applying to the finished product. There’s nothing worse than something coming together and looking great prior to being worn, only to realize at the last minute that shoving an appendage through it and moving causes it to fall apart before you even leave your hotel room. Keep an open mind, be creative, and allow plenty of time to experiment!

Related Posts:

• Cosplay Breakdown: Sewing Machines
• The Art of Styling Wigs
• Crossplay Declassified
• Cosplay Etiquette
• Choosing the Right Costume