Worbla has become a staple in the cosplay community for creating armor and props, but it's not the only option out there, and it's certainly not the cheapest! If you're looking to save money or find materials better suited to specific projects, here are five thermoplastic alternatives that might be perfect for your next cosplay build.
1. Sintra (Expanded PVC)
Cost Comparison
Sintra is significantly more affordable than Worbla, typically costing $15-30 for a 24"x48" sheet depending on thickness, compared to Worbla's $25-40 for much smaller sheets. You get much more material for your money.
Strengths
- Extremely lightweight and easy to cut with basic tools
- Holds crisp, clean edges and geometric shapes beautifully
- Takes paint exceptionally well without extensive priming
- Available in various thicknesses (1mm-6mm) for different applications
- Can be heat-formed with a heat gun for gentle curves
Weaknesses
- Limited flexibility. Best for rigid armor pieces, not organic shapes
- Cannot achieve the same level of detail as Worbla
- Requires edge finishing as the foam core can be visible
- Not ideal for compound curves or highly detailed sculpting
Best For
Sintra excels at creating sci-fi armor, helmets with clean lines, shields, large flat armor plates, and any prop requiring crisp geometric shapes. Think Iron Man, Mandalorian armor, or futuristic weapons.
Where to Buy
Available at sign supply stores, TAP Plastics, professional plastics suppliers, and online retailers like Amazon. Look for it under names like Sintra, Celtec, or expanded PVC board.
2. Terraflex
Cost Comparison
Terraflex runs about $20-35 per sheet, making it comparable to or slightly cheaper than Worbla while offering different working properties that many cosplayers prefer.
Strengths
- More flexible and forgiving than Worbla when heated
- Doesn't require as high temperatures to work with
- Smoother surface texture requires less finishing work
- Can be reheated and reshaped multiple times
- Self-adhesive when heated, similar to Worbla
Weaknesses
- Can be harder to find than other alternatives
- May require more structural support for large pieces
- Slightly less detail retention than Worbla's finest art
- Limited color options (usually comes in black or brown)
Best For
Terraflex is excellent for organic armor shapes, curved pieces, bracers, pauldrons, and projects where you want a smoother finish with less sanding. It's great for fantasy armor and flowing designs.
Where to Buy
Available almost exclusively through Tandy Leather, though there may be other suppliers I don't know about.
3. PVC Sheets (Solid PVC)
Cost Comparison
Solid PVC sheets are incredibly budget-friendly at $10-20 for large sheets, making them one of the most economical options available, often 50-70% cheaper than Worbla.
Strengths
- Very inexpensive and widely available
- Durable and impact-resistant
- Can be heat-formed into curves and shapes
- Easy to cut, drill, and work with standard tools
- Excellent for structural components
Weaknesses
- Requires higher heat to form (heat gun on high setting)
- Can release fumes when heated—work in ventilated areas
- Heavier than foam-based alternatives
- Not self-adhesive; requires glue or mechanical fasteners
- Limited to simpler curves and shapes
Best For
PVC sheets work wonderfully for weapon cores, structural armor bases, large shields, rigid costume elements, and anywhere you need strength and durability. Perfect for props that will see heavy use or need to support weight.
Where to Buy
Home improvement stores (Home Depot, Lowe's), TAP Plastics, hardware stores, and online suppliers. Very easy to source locally.
4. 3D Printing (PLA/PETG Filament)
Cost Comparison
While the upfront cost of a 3D printer ($200-500 for entry-level models) is significant, filament is fairly cheap. Once you have the printer, your per-project costs are much lower than Worbla, especially for detailed pieces.
Strengths
- Unmatched precision and detail reproduction
- Perfect consistency and repeatability
- Can create complex internal structures and hollow pieces
- Ideal for intricate details, small parts, and mechanical components
- Files can be shared, modified, and reprinted
- Growing library of free cosplay files online
Weaknesses
- Requires initial investment in printer and learning curve
- Time-consuming for large pieces (prints can take hours or days)
- Size limited by printer build volume
- Requires post-processing (sanding, filling layer lines, painting)
- Not flexible like thermoplastics
Best For
3D printing excels at helmets, detailed armor pieces, weapons with intricate designs, small accessories, mechanical parts, and anything requiring exact symmetry or complex geometry. Perfect for sci-fi, video game, and anime cosplays.
Where to Buy
Printers available from Amazon, Creality, Prusa, and other manufacturers. Filament from Amazon, MatterHackers, Hatchbox, and local suppliers. Files from Thingiverse, MyMiniFactory, and cosplay-specific sites.
5. Cheap Craft Foam/EVA Foam
Cost Comparison
This is the budget champion! Craft foam mats cost $1-2 per square foot, and even high-density EVA foam runs only $5-15 per sheet making it 80-90% cheaper than Worbla for coverage area.
Strengths
- Extremely affordable and accessible
- Very lightweight and comfortable to wear
- Easy to cut with craft knives or scissors
- Heat-forms beautifully with just a heat gun
- Can create both organic and geometric shapes
- Forgiving for beginners
- Can be textured and detailed with heat
Weaknesses
- Requires sealing (Plasti Dip, mod podge, or wood glue) before painting
- Not self-adhesive; needs contact cement or hot glue
- Less durable than rigid thermoplastics
- Visible seams require more finishing work
- Can compress or dent with heavy impact
Best For
EVA foam is incredibly versatile and works for almost everything: full armor suits, organic shapes, fantasy armor, floor mats for large pieces, layered details, and especially great for beginners learning cosplay construction. It's the go-to for many professional cosplayers.
Where to Buy
Craft stores (Michaels, Joann), harbor freight (anti-fatigue mats), home improvement stores (foam tiles), TNT Cosplay Supply, and Amazon. High-density EVA foam from specialty suppliers like Foam Factory or cosplay stores.
Final Thoughts
While Worbla is an excellent material with unique properties, these five alternatives offer compelling benefits, especially when it comes to cost savings. The best choice depends on your specific project needs, budget, and skill level. Many experienced cosplayers use a combination of materials, choosing the right thermoplastic for each component of their build.
Don't be afraid to experiment with samples of different materials to find what works best for your crafting style. Your wallet will thank you, and you might discover new techniques that take your cosplay to the next level!
