Space Marine Foam Armor Tutorial

This costume project is made completely out of EVA and craft foam. This is a great medium to work with as the materials are relatively inexpensive, easily accessible, and easy to work with.

All painting is done with paint spray cans. So you won’t have to purchase any fancy expensive stuff either.

Here’s a quick rundown of the order of making the armor.


  1. Print and cut out pattern pieces.
  2. Cut out foam pieces using the pattern pieces.
  3. Heat form and shape pieces.
  4. Glue your pieces together.
  5. Paint your armor.


If you are new to working with foam, watch the videos in FOAM 101 BASICS as they cover the essential tools and working with foam basics.

Otherwise, you can get started on the tutorial now.

Project Specific Materials



The key material used to build your costume. It’s a great cost effective material for projects like this.

There are three basic thicknesses you will be using.

3/8” (or 10 mm) anti-fatigue floor mats – 1 or 2 packs of 4.

1/4” (6 mm) foam – 2 sheets at 24” x 48”

2 mm foam – 3 sheets at 24” x 48”

If you can’t source these materials locally, TNT Cosplay Supply is a great place to order from.



One can of whatever color you choose should be enough for most of your painting. But just in case I would recommend going with paints you can source locally. If you run out while painting, it’s quicker to get another can that way.

Paint Used in Tutorial

You should be able to find this paint at home improvement stores like Lowe’s or Home Depot or possibly an automotive store.

  • Dupli-Color Perfect Match Premium Automotive Paint – Dark Blue Pearl (8P4)
  • Rust-Oleum Universal Metallic Paint & Primer In One – Flat Soft Iron
  • Plasti-Dip Black

I would strongly recommend testing and practicing with painting before painting a finished piece.


Elastic and vecro were both used to strap the bicep-tricep armor to the arm.


1” elastic on Amazon



Velcro on