photos by Fotokross by Arndt von Koenigsmarck and eosAndy

This project is sponsored by

Material is ProFoam H 3mm and ProFoam H 5mm from their website. You can buy test sets of the material when you are unsure about it. ProFoam H is really good for detailed armor making. Its hard and easy to dremel. You can achieve hard edges and its super easy to heat form. ProFoam S is what I used for my Serra Angel. It is much more cheaper but also not so good for hard edges. Its bends a lot more easier and is a lot softer than ProFoam H.

Be sure to check it out, they have plenty of different foams! I also got some Flexipaint from them. It is one of the best ways to prime your moving foam armor. This Cosplay was not a long dream, but a dream after I googled Magic: The Gathering angels right after finishing my Serra Angel Cosplay. I’m really happy that craftperium gave me the possibility to make this dream come true.




-ProFoam H 3 mm 5 XL sheets
-ProFoam H 5 mm 2 XL Sheets
-a lot of Pattex Classic Contact Glue
-aluminium foil, duct tape, masking tape
-some old closed plateau high heels
-PVC pipes
-Small pieces of old cosplayflex


My puppet is a bit too small for me, but it was okay for this cosplay.  I started with wrapping my puppet with aluminium foil and duct tape. At this point I thought again that I need to make a ducttape puppet of my body. Would be a lot easier. I will upload a tutorial if I ever build one. When I was finished wrapping, I printed out the reference image and started drawing on the pattern. My first idea was to do single plates. But its much more comfy to do a full bodypart. The main body consists of 16 pieces. I spared the booby part because they needed to be shaped seperately. The details are made with the second layer. It needed to look really 3D, so I used a heating gun on slightly bigger cutted out 3mm foam pieces. I folded and squished it in the needed form and then glued it on the body. Then, I used my dremel to make the edges clean and do more details. The following pictures are just progress pictures without description. You can see here how I built up the main body armor.


At first, I never thought foam can be used to create organic forms. After the first thin foam sheets came in, I played a bit with heatgun and my hands. As shown above, I created a base shape first and glued on the shaped parts. To shape the parts you need to transfer the pattern on your thin foam and cut it out slightly bigger than the lines. Use your heatgun to heat up the foam carefully. Then press it in form and glue it on! For a final touch up use your dremel for the edges and some battle damage and a more organic look. Repeat till cry. I used the same technique for the gloves. I cutted out a piece that can fit over my finger and heated it up. I put in on the glove and scribbled the shape on. A final small amount of heat and some cutting later you have a perfectly fitting foam glove. To make the tips more pointy, I glued on a second part on the bottom and dremeled the top. Then I added some heat and pressed the tip in form. I used normal contact glue to glue the parts on the 100% cotton gloves but I recomend a fabric glue for this. The gloves itself are from ebay and I paid around 3€ for a pair. Contact me if you need more tips for this technique or pictures with better quality.





For the legs I wrapped my own leg with tinfoil and tape again. I drew on the patten for the top layer. Than I created a back piece. It is closed with three clip in the front. The details are now made with the exact same method as the torso. I glued it on the backpiece and the whole part is then closed with velcro tape on the inner side! For the shoes I took some old shoes with heels and glued the hot foam around. After creating some layers I used my dremel to add an organic look. The arms are made with my basic bracer pattern and closed with clips and velcro tape over the clips. 



The wings on this project are pretty challenging. I dont want them movable so I needed to think of dettachable parts. I seperated them in 4 main parts. Every visually part is a single tube with feathers on it. The connections are two different sizes of PVC pipes tucked into themselfes. The inner top parts of the wings will be attached on the wing with velcro tape. You need a lot of pressure to get the pipe into another pipe and otherwise the top parts will be destroyed. For the pattern making you need around 20-30 sheets of paper or a paper role, some masking tape, different colors of copics or eddings, tape and a cutter or scissors. I took my already finished body for measurement and drew the pattern freehanded. It has a total width of 2,4 meters each wing. I cutted away the parts I dont need and started thinking about which feathers can be added on the first segment. The harness on the picture is not the final version. I want to overwork it because I have a feeling that this one here will be too weak. My first plan was to craft 4 seperated segments, but in the end I made 3 segments. So strenghten the attachments, I bought some pipe connections and big screws. You can see them on the more detailed pictures.

I started crafting the first segment. Each feather is cutted out a tiny bit bigger than the pattern. Heat the middle of the feathers and then squeeze them with your hands until you get the texture you want. After this step, simply glue them to the PVC pipe and connect them to the other feathers for more stability. Add some extra foam stripes on the top around the tube.

On the photos above you can already see one almost finished wings. They needed to be stabilized by hand here because the other wing was missing 😛 The follwing photos are the connections between each segment. You can see here how the feathers are glued to the tubes. Ignore the masking tape, its just for fixation during crafting. You can see a small part of Cosplayflex on the second picture. This connection is made by taking a thinner PVC tube and fixing it in the bigger on with the Cosplayflex. Make sure its a hard to move connection! The left and right picture show the connection between top and middle segment. Its glues to the middle section with glue, cosplayflex and a lot of tape. The thinner tube is visible when they are not connected. I simply tuck the top segment in the connection and then I use a screw to fix it.

All connections on the wings on the following pictures

Cover parts on top of the wings

First full fiting and wearing test

Photos and Making procress of the harness will be uploaded soon!

Photo by eosAndy
Photos by Fotokross by Arndt von Koenigsmarck