Difference in Foam Fillers

Here I'll show you 3 different types of foam I tend to collect the most often for fillers. Fillers are used to fill in large gaps in construction, since cardboard loses strength without support in those areas. Above image is how they start out, usually packaging from appliances, electronics, etc. All 3 are dense foams, that can withstand a good amount of weight.


1. The right is a large bubble foam. This carves the smoothest, easiest to glue, and holds its shape best. There is enough flex and memory to move it and avoid breaking. I used this type of foam in my Hylian Shield prop, and the wings of the Master Sword.

2. The middle is styrofoam (like the cups you use in sporting events). This one has the most trouble to carve, because it breaks often if you carve too thinly, leaving a bubbled edge. There is no flex to it either, so unwanted pressure will cause it to break. Hot glue will melt this foam instantly, so its best for rough fillers that don't need details. It's usually the easier foam to find too.

3. The left foam is a small bubble type, similar qualities to the right foam. The edging is a little rougher, but its denser (enough to support my full weight), some flex when carved thinly, otherwise it's a brick. Its strong enough that I can't tear it apart with my hands without force. This is being used for my Volga helmet.


Using the right materials can make your project easier, or a lot harder. However, don't let that deter you from using whatever you have available! Some extra effort might be needed, but it's far from impossible. You can also use cardboard strips in a zigzag pattern, triangle pattern, or whatever shape works for your prop. Foam has the benefit of keeping the prop lightweight, since adding too much cardboard will get heavy fast.