EVA Foam Buying Guide
Everything you need to choose and work with EVA foam — what it is, how hardness and grades work, and how to cut, shape and finish it.
What Is EVA Foam?
EVA foam — ethylene-vinyl acetate — is a soft yet durable closed-cell material used in footwear, sports gear, crafts, cosplay and costumes. It’s soft without being a sponge, comes in a wide range of colours and thicknesses, and is smooth on both sides. Because it’s closed-cell, its tiny air pockets are sealed — so it doesn’t absorb water or sweat, it’s easy to sand and seal, and it springs back after compression. It cuts, shapes, heats and sands beautifully, which makes it a favourite for everything from insoles to full suits of armour.
Why Makers Love EVA
Closed-Cell & Water-Resistant
The cells are sealed shut, so EVA won’t soak up water or sweat. It wipes clean, shrugs off moisture, and is easy to seal and finish.
Lightweight Yet Tough
Soft without being a sponge — it holds fine detail and structure while staying light enough to wear comfortably all day.
Shock-Absorbing
EVA compresses to soak up impact and springs back to shape — exactly why it’s the heart of insoles, padding and protective gear.
Easy to Shape
It cuts with a blade, sculpts with a Dremel, moulds under a heat gun and bonds with contact cement. Few materials are this friendly to work with.
Understanding Shore Hardness
Shore hardness measures how firm a foam is — how much force it takes to press into it — using a tool called a durometer that presses into the surface and reads the depth. Lower numbers mean a softer, more cushioning foam; higher numbers mean a firmer, more structural one.
Shop EVA by hardness: 20–35 Shore C (soft) · 40–55 Shore C (medium) · 60–75 Shore C (firm)
Grade A, B & C
Grade describes the quality and make-up of the foam. All three are smooth and workable — the difference is in colour, bubbles and elasticity.
Grade A
The brightest colour and smoothest surface with very few bubbles, plus the best elasticity. The top tier for finished, visible work.
Grade B
Partly recycled, with a smooth surface and a few more bubbles than Grade A. Still elastic and dependable — excellent everyday value.
Grade C
Made from 100% recycled material — smooth and a little denser, with more bubbles than A. Tough, economical and endlessly useful.
Choosing by Density & Use
Match the foam’s density and thickness to the job. Here’s how our main families of foam are used.
Shop EVA by thickness: 2–4mm (thin) · 5–10mm (medium) · 12–20mm (thick)
| Foam | Density / Hardness | Best For |
|---|---|---|
| Craft Foam | 85–90 kg/m³ · low density | Foam flowers and floral backdrops, party & event décor, kids’ crafts, foam stamps and stencils, plus lightweight jewellery and embellishments. Cut with scissors or a craft knife. |
| Soft · Low Hardness | 20–35° hardness | Comfort insoles, padding, cushioning and protective case inserts. Soft, springy and forgiving underfoot and underhand. |
| Medium to High Density | 40–65° hardness | Cosplay armour, weapons and scenery, plus midsoles and trays. Sculpt with a Dremel, thermoform with a heat gun, cut with a utility knife. |
| Firm · High Density | 70–75° hardness | Footwear platforms, soundproofing and flooring in thick gauges — and, in thin 2–4 mm sheets, cosplay armour plating, weapon detailing and durable straps. Score and snap thin sheets with a sharp knife; cut thick blocks with a circular saw. |
Please note: all EVA foam is supplied as raw material, so sheet thickness may vary by ± 0.5 mm.
Working With EVA Foam
EVA is one of the most forgiving materials to build with. A few techniques go a long way.
Cutting
Use a fresh, sharp blade and let it do the work — score, then make several light passes for clean edges. For thick, firm blocks, a circular saw gives the cleanest cut.
Heat-Forming
Warm the surface with a heat gun until it turns pliable, then bend or mould it over a form. It locks in the new shape as it cools — perfect for curved armour.
Sculpting & Sanding
A rotary tool such as a Dremel carves bevels, textures and detail, while sandpaper rounds edges and blends seams into a smooth finish.
Gluing
Contact cement makes the strongest, most flexible bond — coat both faces, let them tack, then press together. Super glue is handy for quick spot fixes.
Sealing & Painting
Always seal first with a flexible sealer (PVA, Mod Podge or Plasti Dip), then paint with flexible acrylics. This stops the finish from cracking as the foam flexes.
Find your foam
Browse EVA foam by density, thickness, format and colour — or reach out and we’ll help you pick the right grade for your project.
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