Foam Patterning and Construction Techniques
Turning 2D Designs into 3D Shapes

Foam Patterning and Construction Techniques: Turning 2D Designs into 3D Shapes explains how to create your theatrical prop, puppet, or costume design using the unique and tricky medium of foam. Step-by-step instructions, photographs, and explanations illustrate how to translate your design from paper to reality by creating custom "skin" patterns, followed by creation of a foam mockup. The book details how to bring your project to life with varied finishing techniques, including using fur and fabric coverings and dying and painting foam. Numerous supplies, tools, and safety procedures and protocols are also covered.

Table of Contents

Acknowledgements

Preface

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Section 1: The Medium of Foam: Materials, Tools and Safety

Chapter 1: Materials

Chapter 2: Safety

Chapter 3: What Type of Foam to Use?

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Section 2: Design

Chapter 4: An Approach to Design

Chapter 5: Renderings, Working Drawings and Simplicity of Form

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Section 3: Translating Design into Reality: Techniques used in the

Patterning Process

Chapter 6: Additive Patterning: Adding a Surface layer.

Chapter 7: Subtractive Patterning: Cutting away the Surface Layer.

Chapter 8: Speed Patterning

Chapter 9: Free Form Foam Patterning

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Section 4: Determining the Pattern Divisions, "Truing" Patterns and Changing Scale

Chapter 10: Determining the Pattern Divisions

Chapter 11: Transferring Patterns to Paper and "Truing" Pattern Pieces

Chapter 12: Scale: Determining the Size of the Finished Piece

Chapter 13: Formula for Reducing and Enlarging

Chapter 14: How to Enlarge and Reduce Pattern Pieces

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Section 5: Putting It All Together: From Pattern to Object

Chapter 15: How to Bevel Corners and Utilize Darts

Chapter 16: Cutting Pattern Pieces out of Foam

Chapter 17: Gluing and Sewing

Section 6: Finishing the Design

Chapter 18: Fur and Fabric Coverings

Chapter 19: Uncovered Foam: How To Finish

Chapter 20: Detailing and Bringing To Life

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Section 7: This Section Goes Through The Full Process For 6 Projects

Chapter 21: Free Form Reticulated Foam Construction

Chapter 22: Making Two Different Shapes from the Same Foam Pattern

Chapter 23: Patterned Foam Mask

Chapter 24: Patterned Foam Armor

Chapter 25: Patterned and Carved Raptor

Appendices

A. Sources and Supplies

B. Bibliography

Mary McClung has designed costumes, puppets, masks, and sets for theatre, video, and television for over 17 years. As Artistic Director and craftsperson at Animax Designs, she had the opportunity to design and build for companies such as Disney, Children’s Television Workshop, and Universal Studios. McClung has also designed productions with The Dallas Children’s Theatre, The Idaho Repertory Theatre, and The Colorado Shakespeare Festival. She teaches full time at West Virginia University as Professor of Costume Design.