Making Athena’s Shield with Thermoplastics & EVA Foam

In this quick build tutorial I show you how I created my shield for my Athena costume using materials you can find in the resource list below. This shield was REALLY fun to create, especially all of those adorbs dangernoodles! I used silicone molds and Thibra to create the designs on the shield. Thibra is a thermoplastic that is easy to use with a little bit of heat. You can use almost any kind of thermoplastic with these techniques!

Materials Used:
There are two kinds of Thibra: Thibra Fine and Thibra Tex. I used Thibra Fine for this project.

Thibra Fine is:
- Smooth on both sides.
- Low 120º F activation temp means less finger burning and reduced working time for fast quick work.
- Capable of complex curves and manipulation.
- Save your scraps to blend together and re-use!
- Super easy to cut. You can even use a Cricut! Check out my video on how to do this!
- Easy to paint!
- Can be used with a variety of glues
- Sandable
- Biodegradable & Eco-Friendly (YAY!!)
- Non-toxic
- Can be vacuum formed

FAQ:
Q
: Thibra's activation temp is lower than other thermoplastics. Will my costume melt in the sun?

A: Nope! But, as with other thermoplastics, don't leave it in the sun unattended, and certainly don't allow it to stay in a hot car for any period of time if it is warm outside.

Affiliate links:

Thibra: https://www.thibra.us

Tommy Art paint http://diypaint.com

Angelus 2-Thin thinners https://amzn.to/2HPfB3W

Rapid Fill and Fine Finish https://tntcosplaysupply.com/?ref=xkn...

EVA Foam https://tntcosplaysupply.com/?ref=xkn...

SmoothCast 57d https://www.smooth-on.com/

Mold Star 15 https://amzn.to/2JTdWMA

Monster Clay https://amzn.to/2U9uhl1

Learn more about thermoplastics in my book!

I’ve added a huge chapter in my book to show you how to use many kinds of thermoplastics to your costumes. I show you smooth, Reinforced and Pellet forms of this versatile and easy to use material!

Most examples of thermoplastics in my book use MTP from MicroMark. I love this material because it is strong, picks up detail and can be polished with heat and a silicone mat for a super smooth shine.

Check out my book here

Beverly Downen

Beverly of Downen Creative Studios is an internationally published professional author, award-winning cosplayer and creator, crafting high-quality costumes based on pop culture characters as well as elaborate original designs. She travels across the country to host workshops and lectures at events, and has a passion for writing extensive tutorials. In 2018 she founded SheProp, a maker forum for female, non-binary and transgender cosplayers, and is the executive producer of all programming and events. She’s worked with many industry companies including Marvel, Worbla, Smooth-On, PlaidFX and MicroMark and has been featured on Tested, Be Amazed, and NW Nerd Podcast. Her 240-page how-to book Cosplayer's Ultimate Guide to EVA Foam was published in 2022 and is available on bookshelves everywhere.

https://DownenCreativeStudios.com
Previous
Previous

1 Min Tutorial: Adding Leather Effects to EVA Foam

Next
Next

Creating Faux Feathers with Thermoplastics