Working with Foam for Scenery
When it comes to creating budget-friendly set pieces for one act plays, foam can be a versatile and lightweight material to work with. While there are companies like A.M. Designs that will create foam set pieces for you, theatre teachers are always looking to enhance their productions while keeping costs down. Foam is a great option for crafting capitals and scenic elements that can easily be transported for competitions.
What types of foam are best for creating capitals and scenic pieces?
The best type of foam for making set pieces is pink XPS foam. This foam is easily found at your big box stores such as Home Depot or Lowes, making it very accessible to school districts.
I have found that Home Depot is the only store that carries 2" foam and the largest thickness of foam Lowes carries is 1.5". Pink foam is easy to carve and can be cut on a table saw or chop saw for clean lines.
Styrofoam is another option but getting large sheets can be difficult if you already don't have a supplier or they aren't a school vendor.
How can other materials be used to create intricate designs?
Other types of foam that can be used as detail is EVA foam, foam core, polyethylene foam and upholstery foam. These types of foam are much more flexible and great for curves, faux moulding or intricate designs.
I loved using posterboard for covering large areas that needed to curve and flexible moulding comes in a self stick option that makes decorating edges so easy. Plastic garden fencing make great non-metal iron work that would you swear is real.
What techniques can be used to cut and glue foam?
Pink foam is easy to carve if you are wanting a more organic shape and can be cut on a table saw or chop saw for clean lines. Jigsaws also work but know that the cut will be rougher and you'll have to smooth it out afterwards.
I have found that snap blades are be best for cutting and slicing thick foam. Box cutters are just not long enough to get through the piece and end up tearing surfaces.
If you are looking to use a hot knife, I would suggest getting an air cooled hot knife from RoMech. Air cooled knives let you cut longer with out the fear of your tool overheating. Always practice safety precautions with foam as it releases toxic fumes and work with a respirator, in well ventilated areas, outdoors and never downwind of fumes.
My favorite type of glue to use for foam is Clear Gorilla Glue. It is water activated so be sure to mist your pieces with some water, drizzle glue, press, then weight down with some paint cans. This glue doesn't foam up like traditional brown Gorilla Glue so no clamping is needed.
If you are wanting to glue large full sheets of foam, I would suggest using PPG Seal Grip Gripper Paint (formerly knowns as Glidden Gripper). This is actually a paint primer but when used as glue it is much more cost effective than any glue I have found. Simply roll a good coat on on both sides, put the pieces together and weight down overnight. It is remains carve-able and sand-able.
How can foam pieces be made more durable for travel?
To ensure that foam capitals and scenic pieces are durable enough for travel to competitions, consider coating them with a layer of cheesecloth and glue. This will help protect the foam from damage during transport and ensure that the pieces maintain their integrity throughout the production.
I find it helpful to water down your glue just a little bit to make it paintable and tint it with a few drops of paint so it is easier to see. Paint on a layer of glue, lay some cheesecloth on it, then more glue on top and let dry. Work in small sections still your whole piece is covered. Chip brushes work best so you can jam the brush into any corners and get good coverage. That's it. In the event you run into something while unloading or moving, the cheese cloth helps hold everything together until you have time to repair it.
Final Thoughts
By utilizing foam to create capitals and scenic pieces for one act plays, theatre teachers can enhance the visual appeal of their productions while staying within budget constraints. With the versatility and lightweight nature of foam, creating intricate and realistic set pieces has never been easier. If you are interested in making your own basic box for capital, I have a free PDF you can use and a link to the presentation I give at workshops. Enjoy and go make something awesome.