EVA Foam Astronaut Helmet

I was asked if I could make some props for a primary school’s “space” role play corner. If you’re going into space you need a space helmet. The only specifications were, safe for young children to use and cheap. I managed to make one helmet out of a single 60 x 60 cm eva floor mat, a little glue and some paint. I couldn’t find a free astronaut helmet template so I made my own base on a sphere. The helmet is big enough for children, I can just squeeze my adult head into it, but if you want to make it for an adult I would scale the template a little. 

For the basic helmet you will need:

1 60 x 60 cm EVA floor mat

Glue (I used contact adhesive, sometimes called impact adhesive)

Sharp knife (cheap disposable ones are best as floor mats will blunt the knives)

Print out of the template

Paint (I used acrylic paints)

Print out the 2 templates, cut them out and stick the 2 halves of the “A” template and “B” template together

Draw round the templates on the floor mat and cut them out, you will need 3 x A, 2 x B, 2 x C, 2 x D and 2 x E. EVA foam blunts knife edges really quickly, it’s worth using cheap knives and swapping them frequently to keep a clean edge to the cuts. If you have access to a bandsaw that will cut EVA quickly and cleanly 

This step curves the individual panels and helps make the helmet round. You can leave it out, but the helmet will look quite angular.

Gently heat each panel, either with a hairdryer, or a heat gun on low (It’s easy to melt the foam so be careful!). When warm mould the panel over something round, I used the bottom of a mixing bowl. When the foam cools it keeps the curved shape

Glue the sections together, one by one. I use contact adhesive which forms a very strong bond instantly (contact adhesive has a lot of solvent, use outside or in a very well ventilated space!). Spread adhesive on each edge then leave for 5-10 minutes until it’s touch dry. When you bring the 2 glued edges together, press hard together and they will join instantly. Take your time and try and keep the seams as invisible as possible

I glued the sections together in the order A, A, A, E, B, D, B, C

I then glued a strip of foam round the bottom to tidy up the neck.

This is your basic helmet and can leave it at that if you like. I added some rings of foam on either side, that not only hide the seams, but reinforce the helmet. 

Paint. I used cheap acrylic paints, a few thin coats are better than one thick one. I went with traditional white, but here's where you can let your imagination go wild.