How-To: Make Monster and Alien Feet with Expanding Foam

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Make oversized wearable monster or alien feet by building up canned expanding foam around a pair of foam shoes, shaping the toes as you go, and painting the cured forms. Apply the foam gradually: it keeps expanding, so controlled layers are easier to shape than one large application.

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Materials and workspace

This method follows Dave Simon’s October 7, 2009 Make: tutorial, which documents foam shoes covered with canned expanding foam. Simon says he used minimal-expanding foam; the tutorial does not name a brand or establish compatibility with particular shoe materials.

• A pair of old or new foam shoes
• Canned expanding foam; Simon used minimal-expanding foam
• Disposable gloves
• Newspaper to protect the work surface
• Spray paint for the finish

Set up outdoors or in another well-ventilated area, cover the work surface with newspaper, and follow the directions on the foam can. Keep the left and right shoes identifiable as you work.

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Build and shape the feet

1. Apply a first layer. Slowly dispense foam around each shoe, watching how the specific product expands. Begin forming the toes with this layer; Simon’s example has three toes on each foot. Keep the inside edges as straight as possible to leave a more natural walking path.
2. Add foam in layers. Give each application a few moments to begin setting before adding more. Work around the back and top, filling gaps and covering the shoe. Compare the feet as you go so their size and shape remain balanced. Simon’s practical advice is: “The slower you can meter the foam, the easier it is to form into the shape you want.”
3. Let the foam cure. Leave the feet overnight before painting, especially where the foam is thick. In the tutorial, Simon notes that by the next day the feet had finished expanding and looked somewhat smoother.

Paint the cured foam

Once the foam has set, apply spray paint to create the creature’s color and detail. Simon describes using a gray base, flicks of purple and blue, then a green main color, with orange and red on the toes and silver accents. His sequence is one example rather than a required palette. Avoid a heavy final spray coat if you want the earlier colors to remain visible. Let the paint dry before removing the newspaper from the soles.

Safety and practical limits

Wear disposable gloves, work with ventilation, and follow the foam can’s instructions. The 2009 tutorial does not report measured traction, durability, or paint-and-foam compatibility, so it cannot establish how safely or how long a finished pair will perform under particular conditions. Test materials and fit cautiously before wearing the feet.

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Source: Make:, Dave Simon, “How-To: Make Monster and Alien Feet,” October 7, 2009.

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