XPS foam, or extruded polystyrene foam, is a popular material among hobbyists and DIY enthusiasts due to its durability, lightweight nature, and versatility. Available at many craft stores including Hobby Lobby, XPS foam is commonly used for model making, terrain building for tabletop games, architectural projects, and insulation for creative home builds. Whether you are designing a miniature village, sculpting cosplay props, or constructing a custom backdrop for photography, XPS foam offers a flexible and accessible medium to bring ideas to life. Understanding how XPS foam functions and how it can be utilized is essential for any crafter looking to expand their toolkit.
What Is XPS Foam?
Definition and Composition
Extruded polystyrene foam, known as XPS foam, is a closed-cell, rigid foam insulation material. It is manufactured through an extrusion process, which results in a smooth, consistent structure. This gives the foam its durability and excellent surface texture, making it ideal for carving, cutting, painting, and layering in craft and construction projects.
Common Features
- Lightweight and easy to handle
- Resistant to moisture and decay
- Rigid structure that holds shape well
- Comes in various thicknesses and densities
- Typically blue, pink, or green in color
At Hobby Lobby and other craft retailers, XPS foam is often available in sheets or pre-cut blocks, ready for a variety of hobby applications.
Uses of XPS Foam in Crafting
Model Building
One of the most popular uses of XPS foam is for architectural and miniature model construction. Its smooth texture and carveable nature allow hobbyists to replicate stone walls, bricks, roofs, and even entire buildings. With the right tools, fine details can be added easily, offering a high level of realism for dioramas or model railways.
Tabletop Gaming Terrain
In the world of tabletop gaming like Dungeons & Dragons or Warhammer, XPS foam is commonly used to create customized terrain. Its ability to be cut, stacked, sanded, and painted makes it ideal for crafting hills, cliffs, roads, ruins, and fortresses. Hobby Lobby supplies many of the complementary tools needed for this purpose, such as hot wire cutters, acrylic paints, and adhesives.
Cosplay and Props
Cosplayers often turn to XPS foam for armor and prop-making because it’s lightweight and strong. It can be sanded for a smooth surface or heated gently to shape and bend. Once coated with sealing materials like Mod Podge or resin, it becomes sturdy enough for wear or display.
Set Design and Backdrops
For photography or theater production, XPS foam serves as an excellent base for backdrops or props. Artists can carve large panels into rocks, trees, or textured walls. It can be primed and painted to resemble realistic surfaces, all while staying light enough to move or mount easily.
Working with XPS Foam
Cutting and Shaping
There are several methods to cut and shape XPS foam depending on the level of detail required:
- Utility knives: Great for straight cuts and scoring
- Hot wire cutters: Excellent for curved or intricate cuts
- Sanding blocks: Used to smooth surfaces or round edges
Always ensure your tools are sharp to avoid tearing the foam. A gentle touch and multiple passes often yield cleaner results than forcing cuts.
Gluing and Assembly
Because some glues can melt or damage foam, it’s important to choose adhesives designed for foam materials. Hobby Lobby typically carries foam-safe glues, such as:
- PVA glue (white glue)
- Foam tack glue
- Low-temp hot glue
Epoxy can also be used for permanent bonds but should be tested on scrap pieces first to check compatibility.
Sealing and Painting
XPS foam has a smooth surface that can be painted directly, but sealing it first provides better results and durability. Sealing also protects the foam from solvents in certain paints that may degrade the material. Common sealing options include:
- Mod Podge or white glue diluted with water
- Foam-friendly primers
- Acrylic gesso
Once sealed, acrylic paints work wonderfully on XPS foam. Dry brushing and layering techniques enhance texture and realism for terrain or props.
Advantages of Using XPS Foam
Versatile and Easy to Customize
XPS foam adapts to many different creative needs. Whether flat, layered, carved, or shaped, it allows the artist full control over design and finish. It’s suitable for both simple and advanced projects.
Cost-Effective Material
Compared to other hobby materials like wood or plaster, XPS foam is relatively affordable. It provides a large workable surface for a modest price, especially useful for larger-scale projects or prototyping.
Lightweight and Portable
Despite its rigidity, XPS foam is incredibly light, making it easy to transport or hang. This is especially beneficial for costumes, stage pieces, or any display that needs to be mobile or suspended.
Durability and Resistance
When properly sealed, XPS foam becomes water-resistant and durable. This makes it a practical material for long-term display or repeated handling, as in gaming terrain or theater props.
Things to Keep in Mind
Safety Precautions
When cutting or heating XPS foam, always work in a well-ventilated area. The foam can release fumes when burned, so it’s important to avoid using high-heat tools without proper protection. Use a mask and safety goggles when sanding or carving to minimize dust inhalation.
Storage and Handling
Store foam sheets flat to avoid warping. Keep away from direct sunlight and heat sources, which can cause distortion or degradation. Leftover pieces can be saved for future projects, as even small scraps may be useful for detailing or filler shapes.
Environmental Considerations
Though reusable, XPS foam is not biodegradable. To minimize waste, use every part of the sheet and consider integrating scraps into new designs. Always dispose of foam responsibly and explore recycled options if available.
Finding XPS Foam at Hobby Lobby
Hobby Lobby offers a variety of foam materials, including XPS foam in different sizes and shapes. You may find it in the model-making section or near insulation and base craft supplies. If you’re unsure, store staff can help you locate materials suitable for your project. In addition to foam, Hobby Lobby also stocks essential accessories like foam-friendly adhesives, cutting tools, paints, and protective coatings that pair well with XPS foam for hobby use.
XPS foam from Hobby Lobby is a highly adaptable material that serves creators across multiple fields from hobbyists building miniature landscapes to cosplayers designing wearable props. Its ease of use, affordability, and structural reliability make it an essential component in any crafter’s toolkit. With a few tools and some creativity, you can transform simple foam sheets into complex, beautiful, and functional pieces that reflect your personal style and imagination. Whether you’re a beginner or a seasoned creator, exploring the possibilities of XPS foam will open the door to countless project ideas and crafting solutions.