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7

The "aircraft" you reference is made of expanded polystyrene foam, also known as Styrofoam™. It is sensitive to heat to the point that there are high-temperature-based tools to address your goal. Rather than spend a bunch on specialized tools, you can use a soldering iron set just low enough to control the level of melt generated. If you have a ...


5

The mats are common, as you suggest and are composed of EVA foam. Almost every source I've found involves textured surfaces and interlocking edges. This is not universal. Cosplay costume makers use this material for creating various components of costumes, including masks and armor. My brief search returned un-textured foam in 0.25" thickness (6.35 mm) ...


4

What you're looking for is foam interfacing (Pellon Flex Foam, Annie's Soft & Stable, Bosal In-r-Form, etc). This is a soft foam material generally about 1/4" (6mm) thick, designed to be sewn into projects like bags, totes, and hats to provide them with a stable structure while still allowing them to flex--it's meant for exactly your intended use. ...


4

PVA is one common type of wood glue (one global example is Gorilla wood glue), though the product in the video is the cheaper builder's PVA which can be mixed into plaster, or diluted and used as a primer or dust-reducing coating for concrete. I'd expect it to be a little thinner than PVA wood glue, but the latter can be diluted with water. PVA is sold as ...


4

Yes there are certainly foams you should exercise caution around when cutting. And an easy way to check what cautions you need to take when working with different foams is to look up the foam's specific MSDS report. MSDS stands for Material Safety Data Sheet. "A Material Safety Data Sheet (MSDS) is a document that contains information on the potential ...


3

If the only problem with the craft foam is the floppiness, you may have luck with high-density EVA foam. Depending on where you're located, there are a number of online cosplay suppliers who have it available, and I know that TNT Cosplay, at the very least, provides free samples of their foam. Speaking from experience, high density 2mm EVA (the thickness of ...


3

polystyrene foam and similar materials "Similar materials" are basically other thermo-plastics (melt when heated). Whenever plastic is melted a certain amount of vapor is emitted, but generally not enough to be especially harmful - apparently safer than breathing the air adjacent to a freeway. All thermo-plastics that normally make it to consumers are fine ...


3

Casting foam inlays isn't all that different from creating a silicone mold, except the mold is mostly pressure-sealed; the foam creates a lot of pressure, so the mold needs to be strong enough to handle it. The foam is related to Gorilla Glue, so it takes meticulous prep and plenty of mold release everywhere if you want to be able to take the mold apart ...


2

When you suggest that you are using foam rubber, the term invokes many different types of materials with the same name. The density and stiffness of the various choices provide some challenge to a good design. The better options include neoprene and also EVA foam. The latter is relatively inexpensive and can be found in the form of floor cushion squares ...


1

A similar material is used for cheap camping mattresses. It's usually blue. Search for "blue foam camping pad" or "sleeping pad" or "camping mattress" or "yoga mat" etc. Not sure how it compares in terms of price. Make sure you're buying the smooth kind that can be rolled up; there's also a textured kind that folds up ...


1

I would try to use one of the leather hole punchers in the right size. They come in different shapes, for your use I would look for the straight version. Like in this picture. There is also a wider version, which can work well. And if your hole is small enough and near enough the side of the foam, a pliers like tool (as in the picture on this page) may work. ...


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