Foam Armor (Halloween Costume)

Finished Creations
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First posting in finished creations. It is not beautiful, it’s not particularly crafty, but it did work.

My son wanted to build real armor for his Halloween costume (translation - he wants armor and was trying to use Halloween as an excuse). I was able to talk him down from metal to foam armor, but a week before Halloween he hadn’t started…

So I suggested maybe we could get the laser to cut it. I have a stack of 1/2" EVA Foam flooring (2’x2’ squares with interlocking “puzzle” edges). I didn’t know if the laser would cut it or melt it. The answer is it cuts very nicely on my diode laser (Ikier 36w)

Bought pdf plans, imported into LightBurn, traced, cleaned up, etc. Put together with contact cement. Finished off Friday afternoon, but he was happy with the results. Success!

Halloween1
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Halloween2
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Halloween4
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Halloween3
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Just wondering if fake rivets and design etc could be marked on the material. Its a really nice piece of work.

Well done!

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Totally could be done. The foam seems to mark (and I would guess, engrave) well. The original plan was to paint, but the gray foam and glue lines worked well together to look like armor.

It was fun. I can’t wait to make foam inserts for all my tool drawers now…

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