Maya Ellison
There are several ways to shape plastic for cosplay. One way is to use thermoplastics, which can be heated and formed into any shape. Thermoplastics are available in different forms, such as sheets, pellets, and sticks, and can be painted to achieve the desired colour. When heated, they become soft and can be moulded, but when cooled, they harden and hold their shape. Another method is to use acrylic or plexiglass, which is translucent and can be curved or shaped using heat. Acrylic is durable and suitable for props, armour, and wings. Additionally, Wonderflex, a thin plastic sheet with an embedded fabric layer, can be shaped using a mould. Friendly Plastic, available in pellet form, can also be heated and shaped for cosplay sculpting.
| Characteristics | Values |
|---|---|
| Materials | Acrylic/Plexiglass, Polycarbonate, Polyester Resin, Polyurethane Resin, Epoxy Resin, Vinyl, EVA Foam, Thermoplastic, Wonderflex, Friendly Plastic, Worbla Deco Art, Worbla |
| Tools | Heat gun, hair dryer, oven mitts/gloves, safety glasses, craft scissors, hand punch, roller, sanding sponges, soldering iron, blades, clamps, sanders, Dremels, saws, power tools, hand tools, craft cutting board, marker pens, rulers, contact cement, paint |
| Techniques | Scoring, molding, layering, curving, cutting, assembling, priming, painting, soldering, gluing, carving |
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What You'll Learn
Using thermoplastics to create armour
Thermoplastics are a great way to create complex armour for cosplay. They are formable at a low enough temperature to mould to your body without burning your skin. This makes it convenient to create armour with a perfect fit.
To make armour using thermoplastics, you will need some essential tools, such as a heat gun, craft scissors, hand punch, roller, sanding sponges, soldering iron, safety glasses, and gloves. You will also need marker pens, rulers, and a craft cutting board.
Before you begin shaping your thermoplastic, it is important to create a pattern to ensure your armour fits perfectly. One way to do this is by covering the part of your body with cling film and then wrapping it in masking tape. You can then draw the armour shape on the tape and cut it out to make your pattern.
Once you have your pattern, you can start sculpting your armour. For this, you will likely need to use two thermoplastic sheets together to add structure. You can also use craft foam as a base to add rigidity. Heat your thermoplastic with a heat gun and then form it on a dress form or directly on your body. If you are forming it on your body, ensure it is not too hot. Once cooled, your armour will hold its shape.
You can add details to your armour by reheating the plastic and wrapping extra thermoplastic around the back of your foam base. You can also add spikes, borders, and layers by creating them with thermoplastic and bonding them to your armour by heating and placing them where you want them.
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Shaping acrylic sheets
Acrylic sheets, also known as plexiglass, are a great option for cosplay as they are translucent, allowing light to travel through them. They are also durable, rigid, and can hold their shape. However, they can be challenging to work with due to their heavy-duty nature. Here are some important considerations and techniques for shaping acrylic sheets for cosplay:
Cutting Acrylic Sheets
When cutting acrylic sheets, it is important to be gentle as the material can snap and break. One method for cutting is called scoring, where you carve the intended cut line into the sheet and then carefully bend and snap off the piece. This technique is suitable for thinner sheets. For thicker sheets (more than 1/4 inch), the sawing method can be used with a power saw and a plastic or metal-cutting blade. Mark the cut line with a permanent marker or masking tape and use safety gear to protect yourself from debris and noise.
Acrylic sheets can be shaped using the heating method, which involves softening the material with a heat source such as an oven, heat gun, or strip heater. Acrylic starts to soften around 215 degrees Fahrenheit, so a household oven can be used for this purpose. However, be careful not to overheat the acrylic as it can melt at 300-315 degrees Fahrenheit. Once softened, the acrylic can be bent or curved into simple shapes using a mold or form. To avoid distortions in the acrylic, it is recommended to use wool felt on the surface that the plastic will touch. Additionally, when shaping by hand, be sure to use oven mitts or gloves to protect your hands from the hot acrylic.
Sanding and Finishing
Acrylic sheets can have sharp edges, so it is important to sand them down for safety. Sanding can also be used to smooth out jagged or rounded edges, creating smoother lines in your cosplay piece. When working with acrylic, it is recommended to wear eye protection and closed-toed shoes to prevent injuries.
Choosing Acrylic Sheets for Cosplay
Acrylic sheets are ideal for cosplay elements that require a translucent or see-through appearance, such as eye visors, glass-like or plastic-like effects, and floating pieces. They are commonly used for props, armor, and wings. Acrylic sheets can be found in clear or colored varieties and can also be painted to create gradients or details. When deciding on the tools and materials for your cosplay project, consider the advantages of acrylic sheets in creating durable and translucent effects.
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Using vinyl for a flawless finish
Vinyl is a great option for cosplayers looking to achieve a flawless, plastic-like finish on their costumes. It is a simple and cost-effective method that can save you time and money. You can purchase vinyl by the roll from various online retailers, such as Amazon or Wish.com, and it comes in a variety of colours, sheens, and patterns. It is also available in translucent varieties, which can be useful for lighting work or colouring transparent surfaces.
To begin, cut the vinyl pieces according to the shape and size of your costume pieces. It is recommended to add about 1 cm of space around the traced outline to allow for wrapping. After cutting, peel off the backing from the vinyl. Ensure that the surface of your costume piece is clean and free of debris before placing it on the vinyl. Use painter's tape to remove any lint or hair.
Press down on the piece to stick it to the vinyl, and then flip it over. Use a heat gun on low or a hair dryer to warm up the vinyl, softening it slightly. This will help the vinyl adhere better to the surface. If you are working with curved pieces, you will need to heat the vinyl and carefully stretch it over the curves. You can find many online tutorials demonstrating how to apply vinyl to curved surfaces, such as car panels.
Once the vinyl is in place, you can attach multiple pieces together by creating a foam base. Cover the base and the backs of the pieces with contact cement and stick them together. Note that using contact cement should be done in a well-ventilated area or with a respirator, as it is a strong chemical adhesive. Additionally, if you are not attaching the vinyl pieces to anything, you can apply contact cement or another type of glue (except hot glue) to the back of the vinyl to prevent peeling.
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Working with Wonderflex
Wonderflex is a thin plastic sheet with a layer of gauzelike fabric embedded into it. It is a low-melt thermoplastic with an activation temperature of 150°-170° F. It is often referred to as the "celastic replacement" as it is much safer and easier to use, requiring only heat for activation (no nasty solvents).
Wonderflex can be heated and reheated, and will soften within the 150-170-degree Fahrenheit temperature range. It is self-adhesive, so if you heat up two sheets and press them together, they will bond to one another as they cure. The more you heat the material, the stronger this bond will become. You can also use the inherent adhesive to attach decorative fabrics, leather, etc. to the Wonderflex.
Wonderflex can be cut with a good pair of sharp scissors or a utility knife. It can be moulded by hand, but it is recommended that you wear tightly-fitted, insulated gloves to protect your hands from burns. You have about 2 to 3 minutes of work time before it cools off and reverts to its original stiffness. If it becomes difficult to mould and shape as it cools, simply reheat it.
Wonderflex works best when stretched over or pushed into a mould or form. You can custom-make your own mould out of paper mache, or use a rounded plastic bowl or another round object. If you want to make rounded parts, glass jars or buckets work well. For more complex parts, you will need a more complex mould.
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Using Polyester Resin
Polyester resin is a popular choice for creating cosplay armour. It is particularly useful for fiberglassing complicated pieces that have tight bends, where a piece of woven fabric would not lay flat. The curing process for polyester resin generates toxic fumes, so it is important to work in a well-ventilated area or outdoors. When curing resin, it generates heat, so ensure your moulds and work surfaces can withstand this. You can purchase moulds suitable for casting polyester resin, or create your own custom moulds using paper mache or silicone.
Polyester resin is not suitable for use indoors without professional-grade ventilation due to its strong fumes. If you are new to resin, it is recommended to use it in an enclosed space, like a garage, and leave the area for at least 12 hours. It is also advised to use a NIOSH-approved respirator for additional protection from fumes. A fan can also be used to blow fresh air towards you or evacuate air away from the casting.
Polyester resin has a shorter pot time than many epoxies, generally 10 minutes or less. It does not mix in a 1:1 or 2:1 formula but requires drops of hardener per ounce of resin. If your resin is still curing tacky, you can use a resin finishing spray to harden the surface.
Polyester resin is a good choice for creating durable, rigid wearable props. It can bend around curves and conform to shapes that a stiff epoxy resin may not be able to. The surface appearance of both resins is similar, and the differences in hardness, UV sensitivity, working time, and cure time depend on the specific product formulation.
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Frequently asked questions
Thermoplastics are a good option for cosplay as they can be heated and formed into any shape. They are available in sheets or pellets.
You will need a heat gun, craft scissors, hand punch, roller, sanding sponges, soldering iron, safety glasses, gloves, and a mould or pattern.
Cover the part of your body in cling film and wrap it in masking tape. Draw the armour shape on the tape and cut it out to make your pattern.
Vinyl is a good alternative to plastic for cosplay as it is cheaper and available in a variety of colours and sheens.
Acrylic or plexiglass is a good option for translucent cosplay as it is see-through and available in clear and coloured varieties.
