Creating Sturdy and Comfortable Wings for Cosplay

Table of Contents

1. Introduction
2. Materials Needed
3. Step 1: Creating the Back Plate
   • 3.1 Choosing the Right Material
   • 3.2 Cutting Out the Back Plate
   • 3.3 Shaping the Back Plate
4. Step 2: Adding Support Strips
5. Step 3: Attaching Wing Connectors
6. Step 4: Securing the Back Plate with Straps
   • 6.1 Measuring and Cutting the Strapping
   • 6.2 Attaching the Straps
7. Step 5: Strengthening the Back Plate
8. Step 6: Finalizing the Harness
   • 8.1 Covering the Inside with Foam
   • 8.2 Adding Thermoplastic Edging
9. Conclusion
10. FAQs

Introduction

In this tutorial, I will show you my workflow for creating giant foam wings, specifically for the character Hawks from My Hero Academia (BNHA). While this project is a commission, I have received numerous questions over the years on how to make giant wings. Therefore, I will take you through my work process, starting with the creation of the back plate and the wing under structure, and then covering everything with foam. These wings will be static and not articulating, but the techniques can be applied to various cosplay wing designs.

Materials Needed

Before we begin, let's gather the materials needed for this project:

• Sintra or PVC sheeting (3mm thickness)
• PVC connectors (for wing attachments)
• Industrial strength Velcro strapping
• D-rings
• Cyanoacrylate super glue
• Hot glue gun
• Thermoplastic (optional)
• Squishy foam (for interior padding)

Step 1: Creating the Back Plate

3.1 Choosing the Right Material

For the back plate, we will be using sintra or PVC sheeting. Sintra is a brand name for PVC foam sheeting, which is lightweight yet sturdy. If you prefer a more robust back plate, you can use aluminum instead. However, sintra is a great material for this purpose.

3.2 Cutting Out the Back Plate

To begin, trace the pattern of the back plate onto the sintra sheet. You can use a box cutter or craft knife for this task. Since sintra is a dense material, you may need to make multiple passes to cut through it completely.

3.3 Shaping the Back Plate

Once the back plate is cut out, it's time to shape it to conform to the natural curve of a back. To achieve this, heat up the sintra sheet using a heat gun. Please ensure proper ventilation and wear a fume-rated respirator when working with PVC to avoid inhalation of harmful fumes. Bend the sintra sheet carefully to create the desired curve, keeping in mind the comfort of the wearer.

Step 2: Adding Support Strips

To reinforce the back plate and provide stability, we will be adding strips of sintra or PVC sheeting. Cut out strips from the same material and glue them onto the back plate. Cyanoacrylate super glue works well for bonding PVC to itself, creating a strong and secure attachment. Additionally, you can use thermoplastics like Wonderflex or Worbla to reinforce the joints further if desired.

Step 3: Attaching Wing Connectors

For the wing attachments, we will use PVC connectors. These connectors are designed to hold the wings securely in place. Simply slide the foam wings into the connectors, ensuring they fit snugly. If necessary, you can add extra security by drilling holes and using bolts to hold the wings firmly in place. However, for lightweight foam wings, the connectors alone should be sufficient.

Step 4: Securing the Back Plate with Straps

To ensure the back plate stays in place and provides a comfortable fit, we will attach strapping. Measure and cut industrial strength Velcro strapping for the shoulder, under the bust, and lower back areas. Create strap loops that can pass through D-rings and be tightened for a snug fit. The more secure the harness is to the body, the more comfortable it will be for the wearer.

6.1 Measuring and Cutting the Strapping

Take precise measurements to ensure a proper fit for the straps. Cut the strapping according to these measurements, keeping in mind adjustability to accommodate different body sizes. Remember, it is best to sew the Velcro onto the strapping rather than relying solely on glue for durability.

6.2 Attaching the Straps

Using a combination of cyanoacrylate super glue and hot glue, attach the strapping to the back plate securely. Apply cyanoacrylate super glue at the contact points between the strapping and the plate for a strong bond. Use hot glue over the top to reinforce the attachment further. Consider adding additional materials to reinforce the straps if necessary, ensuring the straps are secure and not likely to come loose.

Step 5: Strengthening the Back Plate

To add stability and prevent sharp edges, you can use thermoplastic to reinforce the edges of the back plate. Thermoplastics such as Zebra or Wonderflex can be shaped and attached to the sintra using heat, providing extra strength and a smooth finish.

Step 6: Finalizing the Harness

8.1 Covering the Inside with Foam

To enhance comfort and padding, cover the inside of the back plate with squishy foam. This will prevent discomfort and irritation from the rigid surface. Cut the foam to fit the inner surface of the back plate and attach it securely using an appropriate adhesive.

8.2 Adding Thermoplastic Edging

As a final touch, consider adding thermoplastic edging to cover any exposed edges of the back plate. This will not only give a finished look to the harness but also ensure there are no sharp edges that can cause discomfort or damage.

Conclusion

Congratulations! You have successfully created a sturdy and comfortable harness for giant foam wings. With the back plate securely in place and the straps adjusted for a perfect fit, you are now ready to move on to the wing construction phase. Stay tuned for future videos where I will demonstrate how to cut and attach feathers to create stunning wings for your Hawks cosplay.

FAQs

Q: Can I use a different material instead of sintra for the back plate? A: Yes, if you require a more robust back plate, aluminum can be used as an alternative. However, sintra is lightweight and sturdy, making it ideal for this purpose.

Q: Do I need to reinforce the wing attachments for heavier wings? A: Depending on the weight of the wings, additional reinforcement may be necessary. You can drill holes and add bolts for extra security if needed.

Q: How can I make the harness more adjustable for different body sizes? A: Adding adjustable straps with D-rings allows for easy customization and ensures a proper fit for individuals with varying body types.

Q: Can I use regular glue instead of cyanoacrylate super glue? A: While regular glue may work, cyanoacrylate super glue chemically bonds and melts PVC, creating a stronger and more durable connection.

Q: What is the purpose of the squishy foam on the inside of the back plate? A: The foam provides added comfort and padding, preventing discomfort and irritation caused by the rigid surface of the harness.

Q: Are there any precautions I should take when working with heat and PVC? A: Working with PVC and heat requires proper ventilation and the use of a fume-rated respirator to avoid inhaling harmful fumes. Additionally, caution should be exercised to prevent burns when shaping the PVC sheeting.