Plastazote (EVA) foam is a lightweight closed cell foam which can be formed with heat.
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Plastazote (EVA) foam is a lightweight closed cell foam which can be formed with heat. It is somewhat rigid when it is cold while retaining some flexibility which makes it perfect for things like armour. You can use EVA foam alone or covered with a thermoplastic like Worbla to give it more rigidity.
EVA foam is easy to cut with scissors or a craft knife and a heat gun is suitable to heat the form before moulding.
Look out! Be careful with your tools. A heat gun can fluctuate between 360 and more than 500 degrees Celcius. Gloves are recommended for use when handling hot EVA foam.