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Foam Clay

Foam Clay

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What is Foam Clay?

Air Dry Foam Clay also known as Foam Clay is a acrylic modeling clay, similar to polymer clay, but air-drying, which stands out for its flexibility, lightness, and its ability to fill and disguise joints. This material has become popular for a multitude of applications, but especially in the field of modeling and cosplay, where it is used to create joints and details of armor, weapons, accessories, and other elements that require a professional and light finish.

Unlike other heavier materials such as Worbla thermoplastics or EVA foam, foam clay has the advantage of being moldable and adaptable when fresh, which allows for the shaping of almost any design. Its acrylic base allows you to melt joints easily by simply using water and your finger. Once the material dries (usually 24 to 48 hours), it becomes rigid but remains somewhat flexible and lightweight, making it an excellent choice for large, complex pieces that need to be transported or carried around at conventions or other events.

Once dry, it can be painted with acrylic paints and is easily cut with multiple cutting tools.

How to use foam clay​?

The extreme versatility of Foam Clay makes it perfect for a wide range of modeling and cosplay projects. Here are the main techniques to get the most out of this material:

Hand molding

This is the simplest way to work with the material. Thanks to its soft and elastic texture, it can be easily sculpted and given the desired shape, from small decorative pieces to large armor elements. Perfect joints can be created by applying a small amount of water to smooth the finish. It is also common to use modeling tools to facilitate the creation of more complex details and textures.

Keeping your hands moist will help keep it from cracking or drying too quickly. Also, if the foam clay is hard to work with, you can soften it with a little distilled water. Keep in mind, that if you overdo it, it will be sticky and not moldable.

Using silicone molds

Another technique for using this product is to fill silicone molds. It is much faster than using other materials such as epoxy resin and you can create a variety of very detailed, lightweight, and modifiable designs. To use it in one of your silicone molds, follow these instructions:

  1. Prepare the mold. Make sure your mold is clean. You can moisten it or lubricate it with sculptor vaseline to prevent the Air Clay Dry from sticking.
  2. Apply the Foam Clay. Take a piece of material and place it in the mold pressing it so that it covers the hole completely and every detail is printed.
  3. Remove the excess. Use your hand or, if necessary, a flat tool to remove the excess material outside the mold.
  4. Freeze the material. Place the mold with the Foam Clay in the freezer until it solidifies. You can also wait for it to dry completely at room temperature. Keep in mind that if the piece is very thick the inside may not air dry for a long time, so freeze the piece to remove it.
  5. Unmold. Carefully remove the material from the mold and observe the incredible result.

Using silicone molds is ideal for creating intricate details such as filigree, repetitive textures, or ornamental embellishments that can be applied to armor, dioramas, or any cosplay creation.

Combination with other materials

One of the most used combinations in cosplay of this material is with EVA foam. The EVA material serves as a base of complements on which all the ornaments and details are placed to give the desired finish and get an exact replica. However, it is also possible to work on other materials such as wood, plastic, or metal, although the final weight will increase exponentially.

Joining pieces of different materials

One of the most common challenges in cosplay is to join different pieces in a clean and unnoticeable way. Air Dry Clay is a material that adheres well to itself, making this process easier. For a solid and durable bond, you can use a combination of contact adhesive and a hot air gun, although it is not usually necessary.

It can also serve as a bond between other types of materials or be used to hide the seam lines left by gluing two materials side by side. Simply apply a little Air Dry Clay to the joint and moisten it while spreading it in this space, which, once dry, will have to be painted.

Painting and finishing

Once you have finished molding what you need and everything is ready, you can paint over this material. Before doing so, remember to apply a coat of primer to create a suitable base for painting. Keep in mind that if your work plays with the flexibility of the product you will need to use a primer and flexible paints to prevent them from cracking with use. Finally, when you finish the color, add a coat of one of our varnishes to protect your work.

How long does foam clay take to dry​?

To dry the Air Dry Clay, it is sufficient to leave it at room temperature for about 24-48 hours, although the drying time depends on several factors.

The drying process of Foam Clay usually takes approximately 24 hours but can take several days, depending on the size of the project and the thickness of the material. If you want to speed up the drying process, you can do so by placing your project in a well-ventilated area or near a fan. However, these methods may speed up the drying process too much, causing the product to crack.

Where to buy Air Dry Clay?

Air Dry Clay is most commonly found in specialty craft and cosplay stores. If you are looking for a quality product at the best price, we recommend you to take a look at Green Stuff World Cosplay Shop, which offers a wide variety of Air Dry Clay and other materials for your projects. You can buy our products on our official website, in the network of stores and resellers of our items, and in our ETSY or eBay store.

How to make  Air Dry Clay soft again?

One of the advantages of this product is that it is reusable, i.e. once you have shaped it and it has dried, you can reuse it. Although there are several methods to return it to its original shape, one of the most popular is to:

  1. Turning the foam into small pieces with the help of a cutter and introducing them into a bowl of water. The water should completely cover the material.
  2. Put the bowl in the microwave for about 3 minutes at medium heat, although it depends on the power of each appliance.
  3. Cover it with a clean cloth for a few minutes.
  4. Take the pieces out of the water and try to knead them together as much as possible, although it will be difficult.
  5. Store in an airtight bag for 12-24 hours.
  6. After this time, take it out and knead it.

It may still be a little dry. If so, you can mix it with new Air Dry Clay to bring it to the perfect texture.