Smooth-On liquid rubbers, plastics, foams, coatings and other materials are perfect for cosplay costuming. Make your own long lasting helmets, armor, props, masks, replicas and more.

Our Smooth-Cast series of resins are easy to use, 1:1 mix ratio materials which create high strength prop castings. Clear resins can be used to create optically clear lenses, gems and more. Coating foam with Epsilon™ Pro or Urecoat™ gives carved or sculpted foam pieces an impact resistant, high strength finish. Our Free Form™ AIR epoxy putty can be used to fabricate lightweight armatures or finished pieces.

Looking to finish 3D printed pieces for a costume? XTC-3D™ is the industry standard for self-leveling coating for 3D prints. Using XTC-3D™ results in a 3D printed piece which is impact resistant and has a smooth surface. Build lines are nearly eliminated.


How-To Videos | Application Related Products

Molding and Casting a Cosplay Cloak Brooch
How To Make a Mold For Foam Cosplay Armor
How To Make Cosplay Chest Armor Using FlexFoam-iT!™ 15 SLOW Urethane Foam
How To Make a Mold For a Thundercats Cosplay Prop Shield
How to Make a Wonder Woman Cosplay Breastplate using UreCoat Impact-Resistant Coating
Make Your Own™ Impact Resistant Cosplay Props Using UreCoat® Flexible Urethane Coating
How To Slush Cast a Prop Helmet
Cosplay Tutorial: Sculpting a Hellboy Fist Model for Moldmaking
Cosplay Tutorial: Iron Man Helmet Casting
  1. Free Form™ AIR

    Lightweight Epoxy Putty

    • Starting at £44.29

      *Vat Included
  2. Free Form™ SCULPT

    High Density Epoxy Dough

    • Starting at £45.52

      *Vat Included
  3. XTC-3D™

    High Performance 3D Print Coating

    • Starting at £19.21

      *Vat Included
  4. UreCoat™

    Flexible urethane coating

    • Starting at £22.32

      *Vat Included
  5. Epsilon™ PRO

    High Performance Impact Resistant EPS Foam Coating

    • Starting at £35.58

      *Vat Included
  6. Smooth-Cast™ 57D

    Semi-Rigid Urethane Casting Resin

    • Starting at £29.89

      *Vat Included
  7. FlexFoam-iT!™ 15

    15 lb. Flexible Urethane Foam

    • Starting at £40.12

      *Vat Included
  8. Free Form™ AIR Fire Safe

    Lightweight Epoxy Putty

    • Starting at £156.28

      *Vat Included