Tutorial: Foam Hats for Halloween Costumes

Hats are one of those parts of a costume that are intimidating to many beginners (but they don’t have to be!). Unless it’s a popular character, you’re not going to be able to find your hat in a store. Of course, you can find a similar hat and add details on top of it, but sometimes this just doesn’t do the trick. This tutorial will teach you how to create a costume hat using EVA foam (or craft foam).

Why do I use EVA foam (or craft foam) for cosplay hats? Foam is bendable, unlike cardboard, and it’s relatively cheap and more versatile compared to many other costuming materials. You can even glue panels of fabric to your hat at the end if you don’t want a visible smooth foam base.

• Learn more about the basics of EVA foam and how to use it for cosplay

Most fabric hat sewing patterns can be made with EVA foam. So if you’re looking to make a hat for a costume, the patterns you find at a sewing store are a useful and fairly cheap tool. This will not work with hat patterns that include ruffled or gathered fabric (such as bonnets), since EVA foam cannot mimic fabric in that way.

EVA foam will work excellent for stiff hats like cowboy hats or top hats, and EVA foam is great for creating hats that you want to stay in one shape (such as witch hats, visors, and messenger hats).

Supplies needed to make an EVA foam hat:

• 2mm EVA foam or craft foam
• Paper and writing utensils
• A sharp razor
• Contact cement (or super glue)
• A heatgun
• Sandpaper (or a rotary sanding tool)
• Flex Primer
• Acrylic paint

1. Copy the hat pattern and remove any seam allowance. Since we are not sewing the EVA foam together, we won’t need the extra material that you need when constructing hats with fabric. Some patterns will include a seam allowance and others will not so read the instructions of your particular pattern to know if there is any included. Make sure to also copy over any notches included on the sewing pattern so that you know how to line up the pieces of your hat.
2. Cut the pattern out of your 2mm EVA foam (or craft foam). Use a sharp razor so that you get clean edges on your EVA foam pieces. This will make the next steps much easier.
3. Glue the pieces together. To use contact cement, brush the glue onto both edges that you are connecting. Let it sit for 5-10 minutes until the contact cement gets tacky. Then start at one edge of the EVA foam pieces you are connecting and press them together.
4. Sand the seams. Give your glue an hour or so to dry before sanding the seams and any areas that need to be smoothed out. 
5. Paint your hat and add any details and decorations. If you want your hat to look like a fabric hat, you can glue the fabric to the surface of the hat. If you’re painting the hat, I recommend using flexible primer and acrylic paint since these are less likely to chip and crack as the EVA foam bends.

If you can’t find a sewing pattern that works for you, there are some places where you can find patterns specifically made for EVA foam. For example, Kamui Cosplay is well known for making downloadable EVA patterns, and she has a collection of hat patterns too. Be sure to adjust the patterns according to your own head size.