Best Tools for Crafting with Foam

When you are brand new to crafting or cosplaying with foam, all that you typically need is the foam, a sharp knife, hot glue, and maybe a hairdryer. You are ready to challenge yourself and tackle much more detailed creations—what next?

You could try it with what you have on hand, but having the right specialized foam tools for the craft at hand can completely change the outcome. This can save time, effort, possible tears, and really make the finer details pop!

Tool Suggestions

When you’re ready to step up your foam crafting game, there are a handful of tools that can help you achieve better results. Here are a few of our top tool suggestions to help step up your foam creation process.

Glue Gun

One of the most necessary tools to glue items together, including foam, is a glue gun. There are two kinds of glue guns to consider for your project. Cool melt guns are perfect for thin foam that may otherwise be heat sensitive. Hot glue guns, on the other hand, heat the glue to higher temperatures. This allows for a more generous time frame to work with the foam before the glue cools and begins to harden.

Along with cool-melt and hot-glue guns, there are a wealth of glue sticks, both thick and thin, and even low temp glue sticks made specifically for foam.

Heat Gun

Time to set aside your tired blow dryer and reach for a new heat gun. With certain types of foam, a trusty heat gun is great to have around! You may wonder how you lived without it!

Rotary Tool

You might be familiar with rotary tools by their more common brand name: Dremel. This handheld, motorized tool comes with a wide range of bits for various tasks. You can efficiently sand, grind, cut, and polish with a rotary tool. Many crafters and cosplayers use their rotary tools on foam, worbla, wood, and even PVC pipes.


While you can still use your hands to sand the old-fashioned way or a rotary tool for small areas at a time, a dedicated sander can help with smoothing out large areas. As a cosplayer that may have large props and armor pieces, a sander can be crucial. You’ll want something compact and lightweight, like an orbital sander or vibrating hand sander. If possible, look for sanders that provide options for detailed sanding to easily fit into corners.

Hot Wire Knife

If you know you’ll be cutting a lot of Polystyrene foam, a hot wire knife may come in handy. This tool quickly heats to allow you to slice through foam without issue. NOTE: This is not recommended for any foam outside of Polystyrene

Other Tools to Consider

  • A power drill can make construction and decorating more effortless, as drills come with various attachments to help with many projects.
  • For larger and more extravagant crafts, cosplay, or prop making, a power saw may help cut your construction time in half if wood is involved. A jigsaw with an excellent blade can handle a lot. Jigsaws are also considered one of the safer power saws available.
  • Airbrush painting can take a bit to master, but an airbrush will make it easy to add detail to armor, props, and crafts.
  • Safety is important, so respirators and safety glasses are important. Many of the materials a cosplayer uses in prop making and costume creation can irritate or damage your respiratory system. A respirator will help protect your lungs from harm. You should have one to wear during any process that requires strong-smelling chemicals.

When it comes to working with foam, we are here to help—from tool advice and packaging “how-tos” to our wide selection of foam to cover all your needs!

Posted in DIY, DIY Cosplay, Other Products

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