If you’ve ever made an awesome looking prop weapon out of foam, only to find that it loses it’s shape as soon as you pick it up or swing it around, then you know how important it is to have a strong core material. A strong core will prevent a foam weapon from deforming under it’s own weight, and also allow you to wield it and even fight with it, if that’s what you’re after. With that in mind, here are some of the best core materials for cosplay weapons and props:
- Fiberglass
- Carbon Fiber
- PVC
- Polycarbonate
- Wooden Dowels
- Metal
In this article I’ll go through each one, where to get them, and the pros and cons of each.
Fiberglass
Fiberglass rods are a good option for prop weapon cores because they’re light and strong. They’re also quite flexible though, so for that reason they’re best for small to medium sized props, like swords or daggers. The flexibility is good if you plan to use the prop for fighting, for instance if you’re making a prop weapon for a LARP event. It’s more likely that the fiberglass rod core will bend long before it breaks.
Fiberglass rods can be purchased online or in hardware stores. Kite stores also carry them, if you happen to have a kite shop nearby you. They come in various lengths and thicknesses, and you can get them hollow or solid. If you don’t intend to use the prop for anything other than holding for photo shoots and other light activities, then a hollow core would probably be good enough. If you intend to use it for combat, then I would recommend you go with the solid kind.
The downside to fiberglass rods, especially the thinner kind, is that they are quite flexible, so they won’t do much to support very long props. For long or heavy prop weapons you’ll want something more substantial.
Carbon Fiber
Carbon fiber is similar to fiberglass for a prop weapon core because of its light weight and strength, but it has the added benefit of being more rigid. This can help with longer or heavier weapons. These are often used for remote controlled aircraft, so some hobby stores might carry them. If not, then there’s always Amazon. I’ve also seen people use carbon fiber golf clubs and just cut off the club end. That way you can also use the golf club handle if you want to.
If you decide to use carbon fiber, I would recommend you go with either a thick walled hollow tube, or a solid bar. The reason for that is because carbon fiber can be somewhat brittle, so you don’t want a thin tube that could break and splinter. Carbon fiber can be pretty sharp when it breaks.
PVC
PVC is a great option because it’s so readily available almost anywhere. Chances are that there is a hardware store near you, and they always have a lot of PVC in different lengths and sizes. Usually for cosplay props you’ll want a thinner tube, probably an inch or so, for handle areas. But if you need something thicker, they’ll likely have that too. One downside to PVC is that it doesn’t usually come in thicknesses less than half an inch, so if you want something thinner, like a quarter of an inch, then it might be hard to find.
If you’re making a very long prop, then make sure to get a thicker walled pipe, because PVC is actually pretty flexible. Thicker walled pipes will help to support it at longer lengths. It’s also quite tough, so it could be suitable for some combat if that’s what you’re looking to make.
Polycarbonate
Polycarbonate tubes are used in those high end light saber props that people use for saber dueling, so that should give you an idea of how tough they are. They have a very good ability to withstand impacts. They’re also more rigid and stable than PVC, so you could have a thinner tube for a long prop than you could with PVC.
Some hardware stores should carry polycarbonate tubing, but they might not have a huge variety. I’d stick to online shops or Amazon, so that you can order the exact length and thickness that you want.
Polycarbonate tubes are usually clear, but they do come in other colors. Instead of using them for a core material, you could also use them on the outside of props if you’re making something that calls for something like that. Light sabers are one example, but it can be used for any other futuristic prop that needs that kind of look. It’s high impact resistance will also help with durability if you ever drop it.
Wooden Dowels
Wood is a very good core material for certain props. It’s strong, rigid, and durable. If you’re making a prop that’s meant just for holding or display then wood is a good choice. I wouldn’t recommend it for any prop that you want to fight with, because it can break and splinter fairly easily. Even if you know that your wooden dowel or pole is made of a hardwood, those can still crack or break from impacts if you strike them hard enough, so it’s better to stay on the safe side and not use it for combat props.
Wooden dowels can usually be found at craft stores, hobby stores, and hardware stores. Of course you can always buy them online too. If you need something longer, like a wooden pole, you could use an old broom handle or buy one for fairly cheap.
One good thing about using wood for a core material is that you can leave it exposed at the handle and have a beautiful wood grain pattern. It can be pretty difficult to recreate a realistic looking wood grain, so it’s helpful to have the real thing. You can also carve designs into it, and sand or stain it to your desired finish.
Metal
Last on the list, and for good reason, we have metal. Although I wouldn’t usually recommend that you use metal as the core for a foam costume weapon, there are some reasons why you might want to. For one thing it’s probably the most durable thing you could use. It can also be the most rigid. But that all comes at a cost.
Even if you use an aluminum rod, most metal rods will make your foam weapon heavier than the other core materials on this list. The only two metals I would use would be aluminum or stainless steel, and I would keep them thin so that they don’t increase the weight too much.
If you use a metal core for your prop, then it should never be used for combat or striking. It should be for display only. For a display prop it can actually be a pretty good core, as it will add a nice heft to the prop and be very sturdy.
About Safety
When you choose a core material, especially if you intend to use your prop for fighting or larping, then safety is one the most important things you should consider. Just wrapping the core in foam doesn’t make it safe. Make sure that it’s properly and strongly glued all around with foam so that it won’t protrude. You also want to use a strong and flexible enough material so that it won’t break and poke through the foam.
Also, for the tip of the weapon, it’s good to put some sort of a round cap, or even add a flexible tip to the core so that it doesn’t stab through the tip of the prop. Some people use hot glue and mold it to the end of the core so that it forms a flexible tip a few inches long. If your prop is purely for show, then you probably don’t need to worry about this. However, there’s always the chance that somebody else might handle the prop and not know that it’s not safe for combat or striking.