Making a cosplay helmet is a great way to show off your creativity and bring your favorite characters to life! Whether you’re making an Iron Man helmet or a Stormtrooper helmet, there are several steps involved in creating a unique and accurate piece of cosplay armor. In this guide, we’ll walk you through all of the steps necessary for making a professional-looking cosplay helmet from scratch.

Before you get started on your project, it’s important that you have all of the supplies that you need ready and available. The type of materials that you need will depend largely on what type of helmet you are making, but some common supplies include foam sheets, cardboard, hot glue, scissors/X-Acto knife, paint/markers/pencils/etc., fabric/leather/vinyl pieces for detailing, and straps for wearing your finished product comfortably.

Once you have all of your supplies gathered up, it’s time to start designing your helmet! If you’re going off an existing character design (like Iron Man or Stormtrooper) then it may be helpful to look up some reference images online so that you can get an idea of how everything should fit together when completed. If you’re creating something completely unique then use whatever medium works best for sketching out ideas – pencil and paper works great but digital programs like Photoshop are also useful tools for designing helmets from scratch!

Once you have finalized your design, it’s time to start cutting out all of the individual pieces that will make up your helmet! Depending on what material(s) you are using for construction (foam sheets, cardboard etc.) this process may vary slightly but generally speaking it involves tracing out each piece onto its respective material with a marker pen and then carefully cutting them out with either scissors or an X-Acto knife. Make sure that each piece is cut accurately as this will ensure that they fit together properly later on in assembly!

Now that all of your pieces are cut out it’s time to start assembling them together into one cohesive unit! This process will involve using hot glue (or another strong adhesive) to attach each piece securely together until they form a complete helmet shape – be sure not to rush this step as accuracy is key here if everything is going to fit together properly in the end! Once all of your pieces are glued together give them plenty of time to dry before moving onto finishing touches like painting or decorating.

Before painting or decorating your helmet there may be some additional details that need adding such as vents/greeblies etc., these can usually be made from any scrap materials lying around such as plastic bottle caps or bits of foam sheeting which can be glued onto the surface with hot glue or superglue once they have been cut into shape with scissors or an X-Acto knife. Additionally if straps are needed for wearing purposes these can also be added at this stage by gluing fabric pieces onto either side inside the interior rim of the helmet so they can easily be attached around one’s head once fully assembled!

Now comes one of most fun parts – painting and decorating! Depending on what type of effect you want for your finished product there are several methods available ranging from spray paints & airbrushes through to markers & acrylic paints which can all achieve different effects depending on how they are used – experiment until happy with results before moving onto finalizing step below!

Once fully painted & decorated it’s time for final touches such as sealing any exposed areas with clear coat lacquer – this helps protect against dirt & wear over time while also providing extra strength & durability when worn during conventions etc., additionally any straps should now be attached securely so they don’t come loose while being worn – if unsure consult local craft store staff who should be able provide help & advice regarding types suitable fabrics etc.,

Making a cosplay helmet isn’t just about bringing characters to life – it’s also about expressing yourself creatively and having fun in the process too! With patience and practice anyone can create amazing looking helmets from scratch – just remember to take breaks often when working on projects like these so as not to become overwhelmed by the task at hand. And when you’re done don’t forget to check out Maskky fashion products – we offer high quality products perfect for completing any cosplay look.


What material is used for cosplay helmets?

EVA foam is the perfect material for creating a cosplay helmet. If you’re new to cosplay, a helmet is one of the simplest props to make. EVA foam is pliable and easy to shape using simple hand tools, making it a great choice for a beginner cosplayer.

What is the best foam thickness for cosplay helmet?

We recommend purchasing one or two 0.25-inch-thick foam sheets for your cosplay armor. They will provide extra protection and ensure that your costume looks great!

How thick should EVA foam be for helmet?

EVA foam is lightweight and easily molded, which makes it ideal for creating helmets, crowns, and other headpieces that can be worn for extended periods of time without causing neck pain. To create your headpieces, we recommend using one sheet of foam that is 0.5-inches thick.

What is the best foam for helmet?

EPS is the most commonly used foam for bike helmets because it is strong in impact and lightweight. It is also cheap to produce and easy to ventilate. It was adopted as the standard for bike helmets in 2022.

What do you wear under a cosplay helmet?

To avoid revealing your cosplay underneath, it’s best to wear things that are a nude tone that matches your skin. This especially applies to photographs, where even underwear that is the same color as your cosplay will show through.

Can you use craft foam instead of EVA foam?

Craft foam is the same type of foam as EVA foam, only it is sold in thinner densities and is more flexible. It is generally chosen for fine details instead of being used as a base.