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Costume & Charater

At PJ Bowers, our precision-cut closed-cell foams are the foundation for professional costume, prop, and character fabrication across film, theatre, and themed entertainment industries. Using advanced CNC routing and digital patterning, we transform durable lightweight foam into complex three-dimensional forms that bring creative visions to life.

Costume and Character Design Using Closed-Cell Foam

prop film design

Precision Meets Creativity

Our high-density EVA, EPE, and Plastazote® foams are ideal for costume and set construction thanks to their smooth surface finish, impact resistance, and lightweight flexibility.
These materials can be CNC-routed, heat-formed, laminated, and painted — making them a versatile alternative to traditional sculpting materials like fibreglass or wood.
detailed sculpted foam character design

Why Closed-Cell Foam?

Closed-cell foams resist moisture and deformation, maintaining structural integrity even under heavy use or outdoor performance conditions.
They’re easy to shape, sand, and seal — allowing fine detail and repeatable precision for both one-off characters and large production runs.
film, TV prop model

Applications

Film and TV props.
Theme park mascots and stage costumes.
Museum and exhibition models.
Industrial prototypes and scenic design.
Cosplay and event character suits.

Why Choose PJ Bowers

Decades of experience in foam engineering and CNC technology.
Access to premium closed-cell foams made to Defence and industrial standards.
Local fabrication on the Gold Coast, ensuring short lead times and consistent quality.
Whether you’re building a one-off hero suit, a large-scale mascot, or an immersive exhibition prop, PJ Bowers provides the materials, technology, and craftsmanship to make it real — precisely cut, structurally sound, and production-ready.

All Materials Available at PJ Bowers

EPE Sheet foam product image thumbnail

EPE Closed Cell Foam

A budget-friendly packaging and marine floatation foam. All our closed cell foams are waterproof.
Neolon XPE Sheet Foam Product image thumbnail

Neolon® XPE Closed Cell Foam

Recycled, moisture resistant, long-lasting, flame resistant low density floatation material, construction strong and quality insulation foam.
PE Polyethylene foam sheet product image thumbnail

Neofoam® PE Foam

Highest heat resistance, tensile and compressive strength, impact absorbing with slower recovery quality. Available in multiple densities.
EVA closed cell sheet foam product image

Neofoam® EVA Foam

Good strength with high elongation and conformity. A quick recovery or 'bounce' quality. Available in multiple densities.
a product image showing stiff joint fillers made from a very hard, high density PE foam

Stiff Joint Compressible Filler

Very High density compressible PE foam filler strips, for a more extreme heavy duty expansion joint or gasket.
Bridge foam compression joint, expansion joint, product image thumbnail

Bridgefoam®
Compressible Filler

Expands, contracts and recovers under heavy loads with proven track record in hundreds of road and bridge construction projects.
Neolon XPE tubes, insulation, foil faced options, many diameters available

Neolon® Foam Tubing

Neolon® XPE is extremely versatile, has great insulation qualities and available with and without a foil face.
Neolon XPE backing rod, gap filling, caulking, silicone, many diameters available

Neolon® Backing Rod

Our Neolon® XPE backer rods have a closed-cell foam structure which ensures the backing rod is waterproof, weatherproof and fire retardant.
a close up of Neolon XPE foam

Neolon® Expansion Joint
and Rolls

The famous Neolon XPE foam available as convenient, cut to size concrete expansion joint, or as large roll, with or without a foil layer of peel-off adhesive backing.

Ethafoam®

Unrivaled, high quality packaging and Archival foam. Cushioning against repeated impacts with excellent surface protection and high quality aesthetics.
a close up photo of Whisper acoustic foam

Whisper® Acoustic Foam

Scores a sound absorption rating of NRC 1.00 which is the highest possible rating for sound absorption under the standardised test.
zotefoams plstazote many different colors stacked on top of each other

Zotefoams® Plastazote & Evazote

Produced using a unique autoclave process, the Azote® range includes world-leading technical foam brands Plastazote® and Evazote®.