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[yokitty787]

What kind of material should I use to make armor that is strong yet still light enough that I can wear it for long periods of time. I need to be able to sculpt some details in it with relative ease.

[JasonTerror]

May we see a picture of what it is you're planning on making? You can use EVA foam and get great results. A good way to do it is use "fommies" the craft foam sheets, then layer them as you go. As in making the bottom layer a flat piece, then adding the shapes on to where it will look like it's a cut out shape..

[CapsuleCorp]

It does depend on what you're making.

But generally speaking, you're not looking for one material. With armor, you're looking at a combination of materials that will do everything you want the armor to do. For a lightweight base you may be looking at foam or thin plastic sheets, while for sculpted detail it may be a different kind of foam, or air-drying clay, or something else. Armor (and many props) is best made with a combination of materials, keeping in mind that your base or foundation layer does not have to be the same as the outer finishing layer. What creates the stability, shape, and weight of armor is underneath, but what makes people believe you're wearing armor is the finish.

[char99char]

I suggest reading through the forums and doing some google searches to learn background info. Anyone here who has made armor has done 20+ hours of research. There is a lot to learn.

Also look up characters that have similar armor to see how people have made the cosplays.

Keep in mind - strong + light = potentially expensive. I personally like Wonderflex. Nothing about armor making is particularly easy.

[StabbityBlkMage]

Primarily I've been working with the following materials to make armor:

PVC plastics (sintra)
Polystrene plastics
Insulation foam
Craft foam
Rubber
Apoxie sculpt
Bondo

There are a lot of materials that go into making armor, and each suit is different. I have a lot of articles that I have written for my armor if you want some step by step stuff.

http://junkerscosplay.blogspot.com/

[nathancarter]

Volpin has a lot of good information on his blog and on Instructables. He uses Wonderflex for much of his armor, with Apoxie Sculpt for some of the finer detailing.

http://www.instructables.com/id/Crea...th-Wonderflex/

Wonderflex ain't cheap though.

[~Ichigo~]

Fiberglass resin and bondo is what I use. Light and durable