EVA foam density numbers blew my mind when I looked them up

Honestly I always just grabbed whatever foam I saw in the craft store until I checked the actual density specs online. Turns out the cheap stuff is usually 2-3 lb density while the pro grade cosplay foam from places like CosFoam runs around 6 lb. Tbh it explains why my last helmet felt flimsy after 3 wears. Has anyone else noticed a big difference upgrading to higher density foam?

2 comments

Log in to join the discussion

Log In

2 Comments

kaib182mo ago

Man I once spent a whole weekend on a foam sword that fell apart because I grabbed the wrong density.

1

lindaw122mo ago

Oof, that hurts. Nothing worse than putting in all that time and having it crumble. You know @kaib18, the thing nobody mentions is the glue. Foam density matters but the contact cement is what actually holds it together. If you use the wrong solvent based glue it can eat through the foam and weaken everything. I've had pieces fall apart just because I got impatient and didn't let the glue dry enough before pressing.

6