Convention season is coming, and if you’re working on a cosplay costume, now is the time to finish those last major components.
From armour panels to props and costume accessories, vacuum forming can be a useful technique for creating lightweight shaped plastic components.
Why Use Vacuum Forming for Cosplay?
Cosplay armour often needs to look impressive without becoming impossibly heavy.
Plastic formed over a suitable mould can provide a shaped component that is relatively lightweight and can be finished with paint, weathering and other decorative techniques.
For larger costumes, reducing unnecessary weight can make a big difference when you’re wearing the outfit for hours at a convention.
What Can You Make?
Depending on the design and material, vacuum forming can be considered for components such as:
- Armour plates
- Helmets and costume elements
- Shields
- Sci-fi panels
- Creature components
- Props
- Decorative costume pieces
The exact suitability depends on the design, dimensions and material requirements.
Start with the Mould
The mould is one of the most important parts of the process.
Your former needs to produce the shape you want while allowing the plastic to release after forming.
Complex designs may need to be broken into several components rather than attempting to form an entire costume piece in one go.
This can also make painting, assembly and repair easier.
Don’t Leave It Until Convention Week
One of the biggest dangers with cosplay is underestimating the finishing time.
Creating the plastic component is only part of the project. You’ll also need time for:
- Trimming
- Sanding
- Assembly
- Filling
- Priming
- Painting
- Weathering
- Fitting
- Repairs
Starting early gives you room to make mistakes and improve the design.
From Plastic to Finished Armour
Vacuum formed plastic can provide the basic structure, but the final appearance comes from the finishing process.
Paint can transform a plain plastic panel into metal, aged armour, futuristic technology or almost anything else your character requires.
Weathering can add scratches, dirt, rust effects and other details.
Planning a Cosplay Armour Project?
If your costume needs custom plastic components, don’t wait until the convention is just around the corner.
Talk to Jabro Games about your design and find out whether vacuum forming could work for your project.
Con season is coming—get your cosplay project off the workbench and ready for the convention floor.