In this guide, I will show you how to make patterns for EVA foam digitally and by hand. I will feature several different ways to create patterns so that you can choose the best method for you and for your project.
What is a Pattern
A pattern for EVA foam is like a template or blueprint. It serves as your guide, showing you precisely how to cut and shape EVA foam sheets to craft a specific item. These patterns are the key to ensuring that your cut pieces come together seamlessly to form the desired final product.
As we delve into this guide, you’ll gain insights into the art of crafting with EVA foam patterns. We’ll explore how to create your own unique patterns, delve into the art of effectively using these templates, and provide guidance on finding pre-made patterns online.
You can find all of my EVA foam guides right here if you want to learn more.
How to Make a Pattern
Let’s start by taking a look at how to make your own patterns. I will cover how to make them manually as well as digitally.
But let’s first cover the necessity of reference material.
Reference Material
Reference images are very important even if you want to build something original.
Get as many reference images as you can from every possible angle.
If you are building something from a movie, anime, or game then get all the references of the object that you can. Try to get closeups of the object and images from every angle.
When you are planning on building an original project, it’s valuable to gather a substantial amount of reference materials related to something similar. Consider collecting images and information from objects that were prevalent during the same era or context as your unique design.
For instance, if you’re aiming to construct an original piece like a steampunk armor, study the armor and other items commonly found during the Victorian era during the industrialization. Use similar shapes and a similar design language to your collected reference images to design your original piece.
Some tips for collecting reference images:
- Take Screenshots. If the object is from a game then go into the game and take screenshots of the object from as many angles as you can. If the object is from a movie or anime then take screenshots of the movie.
- Visit the website “Artstation.com“. Artstation is a website for artists to share their work. You can often find official concept art of characters, weapons, or environments there.
- Get the official concept art book of the game or movie. Concept art is often a very good reference because it often shows characters, weapons, and other objects from multiple angles.
- Search for 3D models online. You can often find 3D models from third parties of characters, armor, or weapons. You can then open the 3D model in Blender 3D (a free 3D program), and take screenshots from every angle.
- Search on Pinterest for original ideas. Pinterest is great for inspiration. If you want to build something original but don´t quite know what exactly, then pay Pinterest a quick visit to get inspired.
- Use an image generation AI. You can also use an image AI like Midjourney or Dall-E and ask it to create some images for you. It can be a great starting point for an original design.
Once you have all of your reference images, you can either print them out or go digital with “PureRef,” a fantastic free tool.
Just grab it, start the program, and drop your images in. PureRef works its magic and creates a mood board for you. You can zoom in and out and move stuff around easily with your mouse.
It’s a real gem and I use it all the time!
How to Make a Pattern
There are a lot of ways to make your own pattern. In this book, I will only show the methods that I personally use and that I find the best and easiest to use.
In pattern-making, you’ve got two primary methods. You can either create them manually by hand or go digital using software.
Which method you choose is up to you and depends on the project.
How to Make a Pattern Digitally
I create digital patterns using either Pepakura Designer, Blender or a vector drawing program like Affinity Designer or Adobe Illustrator.
Pepakura Designer
Pepakura Designer is free to use but you have to buy the software if you want to export your pattern. And you have to export your pattern to print it.
But the Pepakura community it enormous and a lot of people offer their patterns for free. Just visit the official Pepakura website under “www.tamasoft.co.jp/pepakura_designer/” and check out their massive gallery. Maybe you find what you are searching for.
If you choose to buy Pepakura then you will be able to import 3D models and “Unfold” them into a pattern for paper crafting. But if you remove the glue taps then you can also use the pattern for EVA foam crafting.
But Pepakura is not as easy as you might think. If you just import a highly detailed model into the program then you will end up with an unusable pattern. You have to simplify the 3D model first by reducing the polygon count.
But what are polygons?
A 3D model is made out of vertices which are simply points in a 3D space. These vertices are connected by lines and when at least three vertices are connected with each other then a plane, also known as face, is created. And that face can also be called a polygon.
For Pepakura we want a 3D model with a very low polygon count.
You can either get a so-called “Low Poly Model” online or you can get a regular 3D model and build a Low Poly version of that. This process is called “Retopology”.
I will not cover how to do Retopology in this article but there are a lot of useful tutorials online that show you how it is done in a free 3D modeling software called “Blender 3D”.
1. Import the 3D Model
Once you have your Low Poly model, simply import it into Pepakura and unfold it.
2. Disable Glue Taps
On the right you can see the pattern and on the left you can see the 3D model. Disable the option “Show Flaps” in the Menu “2D Layout” to remove the glue tabs.
3. Set the Page Size
You can set the page size for the pattern under “Settings” in the menu point “Page Settings”. Here you can choose the size of the paper. You can print your pattern on multiple smaller pieces of paper and glue them together later.
4. Mark the Seams
Under “3D Model” you can use the menu point “Edit Mode” to manually set the cut lines along which the 3D model will be “cut” to make the pattern. Play around with the cut lines until the pattern looks manageable.
You are looking for shapes that are easy to cut and are easy to assemble with EVA foam. Try to avoid many small pieces and difficult-to-cut shapes where possible.
5. Arrange the Pattern Pieces
You can arrange the different pieces of the pattern on the right side. The dotted lines are the outlines of your selected paper size. Arrange them as you wish but make sure that they don´t overlap anywhere.
6. Export the Pattern as PDF
Finally, you can export the pattern as a vector file, an image, or as a printable PDF. I personally, export my patterns as printable PDFs or print them directly from Pepakura.
But What if the Pattern is Still too Complex?
If the pattern has too many small parts then you can use a little trick.
- Simply print the pattern out and construct the model out of paper. Make sure to reenable the glue tabs under the option “Show Flaps” in the Menu “2D Layout” to remove the glue tabs.
- Then mark lines on the constructed model where you want to cut it. Draw marks across these lines. These marks are registration marks that will help you to assemble the model later on.
- Finally, cut along the marked lines and you will end up with a new pattern that is more manageable for EVA foam crafting.
If you can’t lay a part flat on the ground then you have to add another cut. I found that this process will often give much better and easier-to-assemble patterns than Pepakura can generate.
And with that, you have your first self-made pattern! Just glue it together and cut it out.
Blender 3D
I learned this trick from Kamui Cosplay. Make sure to check them out, they are real pros and have a YouTube channel that is a pure goldmine for anything cosplay.