The more I work with EVA foam, the more I notice that there is an increasing variety of foams. If you're starting out in foam armor builds, this can be incredibly confusing. I have bought the wrong kind of foam for a build on multiple occasions because I wasn't aware of the differences.
With this in mind, a small blog post on the different types, where to purchase them, and their pros and cons seems to be in order!
Craft Foam:
Usually found in 2mm-4mm sheets, its slightly more porous than High Density EVA foam, and is particularly great for small details or as a stabilizer for worbla projects.
Where to purchase:
Craft stores like Michaels, Joann's, and HobbyLobby
Walmart
Pros:
Flexible
Light
Easy to find
Inexpensive
Comes in fun colors
Cons:
Does not hold heat forming well unless attached to a thicker piece, or coated in mod podge/wood glue
High Density EVA foam (EVA 38 and 60):
My personal favorite kind of foam to use for armor and prop work. It's stiff and much more durable than other types of foam. It's less porous than craft foam and L200 so it sands very well. Also you can now purchase textured sheets, which is super cool.
Where to purchase:
Joann's (YayaHan's Cosplay Line)
Pros:
Heat forms well
Carved designs and details show up really well when heat treated
Sands well
Easy to purchase in large quantities
The thicker sheets (10mm) can be glued together and carves into prop weapons
Cons:
Expensive
Must be ordered online
L200 Foam:
Softer and more porous than HD EVA this product is very similar to the Gym Mats that are so popular with FoamSmiths.
Where to purchase:
Lumin's Workshop (Formlite EVA)
Pros:
Smooth on both sides
Is very flexible
Heat forms well
Cheaper than HD EVA on some sites
Comes in multiple thicknesses
Comes in rolls not sheets
Cons:
Must be ordered online
Does not sand well unless alternating between heat forming and sanding
Gym Mats/EVA Foam Tile:
This is very similar to L200, it is softer than HD EVA and a bit more porous on the smooth side. It is often used for Mass Effect or Halo armor due to the texture found on one side. It is also a popular material for prop weapons.
Where to purchase:
Pros:
Easy to find
Relatively affordable
Durable
Heat forms and sands well
Textured on one side smooth on the other.
Cons:
A little wasteful, you lose a tiny bit of usable area due to the puzzle edging
Textured side may need to be sanded if using for a prop
For tips and tricks on working with foam, please check out EVA Foam: 101.