The head is often the most recognisable part of a mascot costume. Its outline, eyes and facial expression need to reflect the original character design. Before the outer fabric is applied, makers build a structure that establishes those features.

EVA structures

EVA foam can be cut and shaped to form a lightweight head structure. It is useful for designs that need a clear outline or defined three-dimensional features. Once the structure is assembled, the outer fabric and facial details are fitted over it.

Foam carving

For some characters, foam is sculpted to refine the shape of the face, cheeks or other prominent features. Carving can be considered when a design has more complex contours or needs careful attention to its expression. Because this work involves shaping and fitting the head by hand, the design can affect both production time and cost.

Choosing a construction method

The choice should start with the artwork, rather than a preferred material name. A simple rounded character and a detailed animal face may call for different approaches. Visibility, head balance, ventilation and the way the costume will be worn should also be considered.

If you are evaluating a custom mascot, ask to see the head from the front, side and inside before it is covered. These views make it easier to understand its shape and construction.

Send us your character artwork, and we can review which head structure may best reproduce its key features.