First, the pattern was drafted by covering the cosplayer in plastic wrap and then tape, drawing out where the armor would fall across the back, chest, and then arm. The tape and plastic pattern is then cut out, and transferred onto fun foam and Worbla.
The foam is then sandwiched between the Worbla sheets for stability. Each piece is layered together following the pattern. The spine is attached by strips of elastic that are glued into the underside of the panels with more Worbla. This lets the spine move and sway while still holding the shape. D-rings are added to the bracers for strapping that will keep them closed.
The mask is a great example of layering Worbla. The frame was made separate from the eyes and mouth, then attached. Then the forehead and lower jaw were attached, with layers of Worbla adding more depth and detail. Finally, a large sheet was heated and draped over the entire form to even out the layers but keep the depth, making a seamless but 3-dimensional mask.
More details including the creation of the staff, formed by carefully molding pieces of Worbla over carved Styrofoam. Be warned you can’t use a heat gun on Styrofoam directly! It will melt! Instead heat your pieces separately and then add them to your form. Then everything was primed, then painted.
Worbla’s Black Art Home Décor by Hendry’s Art (IG) (YouTube). Some of the smoothest work with Black Art we’ve seen, check out our collection of his videos here.
Little Worbla sculptures including a precious Toothless by Nightshift Cosplay
Ravenna crown from Snow White and the Huntsman by MeltingMirror.
General Wukong from League of Legends mask by Eminence Rain who used Worbla’s Finest Art for the face and Worbla’s Transpart for the eyes and crescent headpiece.
Here you see a stencilled mask & its pattern. After cutting it out it was heated up with a heat gun
After moulding it some edges and rims has been grinded and made round. At the end, the "Black Bat" mask was coloured with acrylic and varnish
This mask modelled directly on the face for a superhero cosplay. If you play a little bit with the activation temperature you can regulate its mouldability very easy
A mask made of Worbla's Finest Art is so light you can glue it to your face
Sorsha Helmet from Willow by Avianna photos by Swoz
we put the Worbla's Finest together with the fabric in between two layers of baking paper and ironed it. Afterwards we moulded it onto this ceramic head
Saviours Hide/Hircine from Elder Scrollsby Pipa Wolf won Judges Choice at the MCM Manchester Comic Con
I made a mold of my body using gaffer tape, then drew on the rough shape of my armour, which I then cut out and transferred the pattern onto foam sheets. (The foam sheets were later sandwiched inside the armor for strength)
Here are some pieces with the foam sandwiched inside, before and after fusing the Worbla layers:
I then adjusted the shape until it resembled the base shape I desired.
I then added accents using the Worbla; any leftover pieces were molded into studs, spikes and rings.
Priming the armor:
Painting the base coat and weathering the bodice.
The leg armor in progress.
Leg armor with spikes and fur added.
Leg Armor, painted and weathered.
The finished leg armor.
The finished costume:
The Worbla was really easy to work with and I’m really happy with the end result, it was my first try at making armour and using Worbla and I’ve had incredible feedback from fellow cosplayers. It has actually encouraged a lot of people I know to get into cosplaying and making bigger projects.
This D3 Demon Hunter armor was made by Lightning Cosplay – and you can see the process of how she created it below!
Worbla's Finest Art had been cut into shape, activated by hot air and modelled manually. Finally they have been painted with acrylics
The parts of the armor are moulded and coated with acrylic primer. Silver spray-paint is used as grounding, then some black spray-paint is used to finish the ground coat. Afterwards the details are painted by brush
The most important thing is to have a draft especially when a lot of single parts are involved e.g. for making the breastplate
Leather stripes were used to connect the front & back part of the breastplate and in addition D-rings were affixed at the plate to connect it with the pauldrons
Here you can see the pauldron's horns laminated with paper & glue plus a lot of ornaments made with Worbla's Finest Art
Horn decorations also made with Worbla's Finest Art
This is how the breastplate looked like after painting
corsage and a belt made of two layers of Worbla's Finest Art. This way it was stable but still flexible
On this mace the thorns at the handle and the stabilizing middle part of the upper hammer are made of Worbla's Finest Art
Dagger by Cast4Art WorkStation
This spraypainted dagger with leather handle weights less than 500 grams
The uncoated Trolls's dagger made of rolled plates. The bent guard plus inner parts of the handle made are of blended leftovers of Worbla's Finest Art
The blade had been cutted into shape and at severals parts I used up to 3 more layers as ornaments.
I used a very thin sheet metal to stabilize the blade of a dagger made of Worbla's Finest Art. I folded the material with the "glue side" inside, activated it with hot heat and connected it on the clean ground with a rolling pin. To prevent sticking together, I watered the floor and the rolling pin a little bit.
Here you can see how the protection for the upper leg part was made
LadyShu Cosplay as Serah with the finished accessories - Photo by Ailuropoda Melanoleuca Photography
For the necklace of her Serah Cosplay LadyShu used a mould of gypsum to make two hemispheres of Worbla's Finest Art. Afterwards they were glued together