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Foam Patterning and Construction Techniques


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Table of Contents

Table of Contents




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

Chapter 1: Materials

Chapter 2: Safety

Chapter 3: What Type of Foam to Use?


Section 2: Design

Chapter 4: An Approach to Design

Chapter 5: Renderings, Working Drawings and Simplicity of Form


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


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


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


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


A. Sources and Supplies

B. Bibliography

About the Author

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.

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