TV Head Cosplay Pattern: EVA Foam Helmet (PDF Downloadable) +Updated Instructions+

***You will need the following:***
1. Printer Paper – 8.5” x 11” inch US Letter paper (Default .PDF template is US Letter)
.PNG files of each piece and instructions are included so you can create a version that will fit on other page types (A4, Legal, etc.)

2. Printer

3. Scissors & Craft knife, X-acto knife, or Box cutter

4. Painter’s Tape – OPTIONAL
(To help hold pieces together & minimize damaging the foam’s surface once removed.)

5. Three 14” x 39” EVA Foam Sheets**– I’d suggest 6-8mm thickness but it doesn’t need much curling, so even 10mm is fine if that’s what you’ve got.
*If you can get 1 to be a slightly longer sheet that is 14” x 41” or 14” x 50” you can use that one for the long Outer Rim piece with 0 seams but that is an unusual or likely unavailable size.
Please see the TEMPLATE LAYOUT section for more information.

6. Blow Dryer, Embossing Heat Gun or Standard Heat Gun (For shaping foam. Optional but will help with shape a lot.)

7. Craft Wire or Small Wooden Dowel (For the base of the antennae, optional.)

8. Sand Paper - OPTIONAL (To sand the edges smooth after assembly)

9. Craft Foam / Fun Foam - OPTIONAL
For the Antenna and Nose, it’s thinner EVA foam and may be easier to shape and result in even lighter pieces, but you can still use a thicker foam.
(You can buy this at Dollar Stores, Wal-Mart, craft stores. Etc.)I

10. Paint – Acrylic is fine. You’ll need the colors you want to use, which depends on your design! DO NOT use spray paint without sealing your foam first!

11. Adhesive Options:
1. Contact Cement – Great for EVA Foam builds but the fumes are potent, prolonged skin contact is bad. [REQUIRES A NIOSH APPROVED N95 HALF MASK ODOR/PARTICULATE RESPIRATOR and fresh cartridges, gloves, & eye protection. ]

2. RECCOMENDED: Hot Glue – Hot glue will likely work fine for your build, especially on thicker pieces
with more surface area to spread it out onto, but it cools quickly.
A high temp gun may melt the foam a bit so make sure you keep the glue only on edges that meet and try not to let it squeeze out between the pieces (You can wipe it away while still warm with something like cardstock.)

4. E-6000 – Pretty classic adhesive gel but needs to sit to cure. Be mindful of fumes.

5. Epoxy Glue – Probably a bit overboard but I don’t regularly work with foam. I’ve used this to glue teacups to their dishware for a prop.

6. Other Craft glue – This list is pretty much all I know, but I’m sure there’s a good tacky crafty glue.

TIPS:
**Finishing Up:**
This will be more helpful than I can be: https://www.youtube.com/watch?v=ug6Rs06FEpk
I don’t know much about painting or finishing foam. You’ll likely want to prime it with white craft paint, and then paint it in the colors you want it to be.
Do NOT use spray paint directly onto the surface of the foam. Most foam will melt and have the surface ruined by what is in the propellant. If you want to spray paint, SEAL your foam first.
Hit it with heat to help shrink the pores on the surface, and then use something like Mod
Podge to give it a primer layer to protect the foam.

Because EVA foam can be shaped with heat, I STRONGLY advise against storing any foam
or heat sensitive crafts in a shed that isn’t climate controlled as it can possibly deform under it’s own
weight if left to sit in a hot climate.

Made with love for my bestie with Tenna brainrot. <3

This download includes
- .obj file with texture (For reference, not suitable for 3D Printing
- .PDF file of printable pattern (pre-cut for 8.5" x 11" inch US letter size paper printing
- .PDF File of basic construction steps & list of materials and tools needed
- .PDF file for resizing. (It's for 3D Prints, but the same process applies, here you'd just scale up the pattern pieces yourself.)