What are Cosplay Thermoplastics?

Cosplay thermoplastics are materials that become soft and moldable when heated and harden again upon cooling. These materials are widely used in thermoplastic sheets cosplay to create armor, props, and intricate details because they are lightweight, durable, and easy to shape.

Some examples of the most well-known thermoplastic materials:

• Worbla thermoplastics – A popular material manufactured in Germany by Rhenoflex that can be shaped easily and reinforced with layers. This material includes a filler of sawdust that gives it a grainy texture that requires sanding and its beige color. This product is considered a product for very rich people because of its high price due to the long chain of commercial intermediaries that raise the price. The material is good, but there are alternatives similar in performance and much cheaper.
• Wonderflex – A strong and flexible thermoplastic that contains an embedded mesh for extra durability. The inner mesh generates a texture with a pattern of small squares that is difficult to conceal. The hardness is acceptable but unless you are looking for exactly that texture, it requires the application of a high-coverage filler to obtain a smooth finish.
• Fosshape – A fabric-like thermoplastic that stiffens when heated, often used for lightweight structures. This product activates at 90ºC (200º F) like all others, but is highly porous and has shrinkage after activation. Its main advantage is its breathability.
• Kobracast Art – It belongs to the Worbla Thermoplastics family and includes an internal mesh, but much finer in thickness. It is normally used for making plaster molds and for sewing. Like all materials with internal mesh, it must be sealed with a thick primer or sealing paste for a smooth finish. Its price like all its family is prohibitive. 
• Sintra (PVC Foam Board) – Rigid material easy to cut, workshop, glue, and paint. You can use the expensive commercial brand, or just look for regular foamed PVC. There is no difference. 

A new Cosplay moldable plastic making waves in this world of Fantasy and imagination appears: ThermoArt, developed by Green Stuff World. It offers superior flexibility, reusability, and ease of molding compared to traditional thermoplastics.

• ThermoArt – is manufactured in 2 versions smooth and standard. The standard version is manufactured with very fine-grained mineral fillers that maintain the hardness of the previous materials, but improve their finish. It needs the same 80/90ºC as the rest to be able to work them. The Smooth version does not have the grained finish of the rest and does not have an interior cloth, so it will not be necessary to sand or fill with a filler. Another great advantage is its low price. Buying directly from the manufacturer without intermediaries allows you to get the lowest price on the market. 

How do you heat and shape Cosplay moldable plastic?

To shape thermoplastic sheets cosplay, follow these steps:

1. Heat the thermoplastic using a heat gun, hot water, or an oven (depending on the material’s heat tolerance).
2. Mold the material while it's soft. You can use your hands, molds, or even press it onto existing objects.
3. Let it cool to harden into its final shape. Some materials, like ThermoArt, allow for multiple reheating and adjustments.
4. Prime and paint the surface if necessary, especially for materials with rough textures like traditional Worbla which is a bit of a nightmare as it requires a lot of post-processing work to achieve a smooth finish.

What are some advanced techniques for working with thermoplastic sheets Cosplay?

For experienced cosplayers, here are some pro tips:

• Layering: Stack thermoplastic sheets cosplay for extra strength, especially for armor.
• Sculpting: Heat small pieces of thermoplastics and shape them with sculpting tools.
• Embedding: Place LED lights, fabrics, or wires between layers of material for added effects.
• Texturing: Use stamps, fabric, or sculpting tools to imprint details before cooling.
• Sealing & Painting: Use spray primers, acrylic paints, or airbrushing for the best finish.