Costume Musings

Thermoplastics panel at Costume-Con 32

We are happy to invite all to our Thermoplastics panel at Costume-Con 32.

It will be held on Saturday April 26 at 12PM.

panel

We will talk about Wonderflex, Worbla, Fosshape, Kobracast and Friendly Plastic.

Free product samples will be available.

See you there!

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Get Kamui’s book for free

NOTE: This promotion is now closed. Thanks for participating.

Are you checking your list and looking for gifts for your friends?

Well… then we have a gift for you!

When you buy a Gift Certificate (min $100) or 2 Jumbo sheets of Wonderflex or Worbla, we’ll give you Kamui’s “The Book of Cosplay Armor Making” for free!

 

book

This is how it works:

  1.  Place an order for qualifying items
  2.  Enter the code *book* (including asterisks)  in the comments section of the order form during checkout
  3.  You will receive an email with download instructions
  4.  Download the file and save it carefully (link is only available once per order)

This amazing book is a valuable resource for anyone interested in Cosplay, Armor Making and Thermoplastics.

Gift Certificates have NO expiry date, can be forwarded to anyone, and can be used towards any product in our site.

 

 

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Most Frequently Asked Questions

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Cutting, folding and fusing Worbla with a Hot Knife

In this time-lapsed video we show how easy it is to cut Worbla with the sharp edge of a hot knife, how to fold worbla using the dull edge, and how to fuse worbla joints with the side of the blade.

(Recording was sped-up 8 times)

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Cosplay armor with Worbla by Electric Alivia


Cosplay armor with Worbla by *Electricalivia on deviantART

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More tests with Worbla

As many people have never worked with thermoplastics, it can be a bit intimidating to figure out how you could use these products.  So here we have some examples to show the basics of using Worbla.

In this post we are not working on any particular craft piece, we’re just showing how the material responds in basic situations.
Here’s another demo of basic functions you can do with Worbla. Today we’re making a mask with some cutout details and edging.

Forming

First, we set the styrofoam wig head in a box for stability so it wouldn’t roll around while we worked.
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Then we applied a piece of aluminum foil to the wig head, to keep the Worbla from sticking to the foam.
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Heated for a few seconds with a heat gun (or a bit longer with a hairdryer), the Worbla can be easily shaped into a mask. To cool and harden it faster, we used a sponge dipped in cold water.
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Cutting

We then shaped the corners using normal scissors.
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You can easily poke a hole for elastic or string using a hot soldering iron or woodburning tool.
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Cutouts

We used the soldering tool to first mark the eyeholes, then dragging the tool to melt the eyehole lines. (If you wish, the edges can be further cleaned up by using small sculpting tools while the Worbla is hot.)
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Here we marked an eyebrow line and cut a slit in the Worbla using the soldering iron tip.
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Edging

Now we’ve taken all our scraps, and we’ll be heating them and using them as putty.
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Heated, the scraps can be rolled into a ‘noodle’ to use as edging or details.
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You can see more information here: Worbla.

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Worbla Tests

As many people have never worked with thermoplastics, it can be a bit intimidating to figure out how you could use these products.  So here we have some examples to show the basics of using Worbla.

 In this post we are not working on any particular craft piece, we’re just showing how the material responds in basic situations.

To fold, crease and cut:

When cutting large pieces it’s very easy to fold the material, mark the crease and cut on the line using regular craft scissors.


cut

You can also mark the cutting line using a ruler and pencil instead of folding first.

Heating:

Worbla responds to heat and becomes very flexible. Here we show the initial stiffness of the thermoplastic, and how it changes after a few seconds of heating with a heat gun.


Once the piece cools down and hardens, we can turn it around and heat it again to flatten it out.

 

A regular hair dryer can activate Worbla too; it just takes a little longer to heat the Worbla.

Basic shaping:

Here we see how Worbla can stretch to take a convex shape.  While hot, it can be molded over objects or pressed into a concave mold.

Once it cools, it hardens and keeps the shape:

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If we don’t like the shape, we can reheat it to flatten it again:

 

Here it is after it cools down:

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Folding and layering:

The material sticks to itself when hot, which is very useful if a thicker and stronger piece is needed:  Just heat and press a few layers together to create a stronger sheet.  This is recommended if you’ll be stretching the Worbla over a larger domed surface, as stretching a lot will thin the Worbla.


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Embossing:

Here we see how easy is to emboss Worbla once it’s hot:

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We hope these notes are useful. We’ll be trying new techniques soon, so stay tuned!

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