Create a layered foam bracer

Draft a measured base, form it, add raised trim, and check the fitted and printed results.

These instructions are for Armorsmith Designer 2.1.1.0. Earlier versions, including 2.1.0.10, can show different panels and labels.

Build a practice bracer from a 180 × 100 mm base with two 40 × 25 mm raised pieces. Use 6 mm foam for the base and 2 mm foam for the details. These are practice dimensions; fit the finished design to the wearer before using final material.

1. Draw and size the base

1. Open Workshop and create a blank workspace.
2. Use Create → Rectangle above the 2D view and complete a rectangle.
3. Select it and open Inspect. Set Width to 180 mm and Height to 100 mm, using equivalent values if your display units differ.
4. Right-click the closed outline and choose Promote To Foam Pattern.
5. Click Edit Foam and set Thickness to 6 mm on the Pattern tab.

Check: The flat outline is visible in 2D and a solid appears in the 3D preview. If the preview is hidden, enable Foam in the pattern tools.

2. Refine the cut outline

Open Edit Shape and choose Vertex or Segment to make a small change to a corner or curve. Keep the outline closed and avoid crossing edges. Use Edit → Undo if the change damages the outline. Click Done, then reopen Edit Foam.

3. Form the bracer

1. On Pattern, choose Horizontal Bend in Form.
2. Set Bend (Degrees) to 90.
3. Orbit the 3D view to inspect the bend. Use Advanced Forming → Reverse Forming Direction if it bends the wrong way.
4. Release any slider and let the final preview settle.

Check: The formed piece changes in 3D while the flat cut outline stays available in 2D.

4. Finish the base edge

In Edge Finish, choose Angle Cut (45 Degrees), set Units to % Of Foam Thickness, and Depth to 50. On a 6 mm base, this means 3 mm down and 3 mm inward. Orbit to inspect the edge.

5. Create the raised pieces

1. Create two more rectangles. In Inspect, size each to 40 × 25 mm.
2. Leave them apart in the 2D cutting layout.
3. Select the base, open Edit Foam → Layers, and choose Use Selected Pattern As Base if needed.
4. Click Add Layer and select that layer as the destination.
5. Use Choose Patterns… to select the two closed rectangles and confirm their addition.
6. Double-click each raised pattern row to open Pattern and set its Thickness to 2 mm.

Eligible outlines are promoted when added. If a piece is rejected, read the message and check its size, closed outline, and fit within the base.

6. Set height and placement

Select the layer and set Height Above Base to 0 mm, so the raised pieces sit directly on the base’s outer surface. This value excludes the base’s 6 mm thickness.

Select a raised pattern in the 3D view and use Translate to move it across the base with local X/Y handles. Use Rotate for local Z rotation. Keep its whole outline inside the base. Move the second piece similarly.

Check: Both pieces follow the bend. Their assembly positions change without moving their flat paper templates. Use Undo/Redo to check one placement edit.

7. Color and inspect the stack

Give the base a neutral Preview Color and the trim a contrasting color. Use a layer color action for a common starting color, then override one selected pattern if useful. A shared edit applies to the selected targets, so check the target name first.

Give one 2 mm detail a Rounded edge at 50% depth for a 1 mm radius. Inspect it from the side. Move Up/Down changes layer list order, not physical height.

8. Fit and save

Enable Attach As Part for the base and attach the workspace to a forearm slot when needed. Use Refresh Costume Meshes after changing the patterns, then inspect the generated part in Costume. Refresh preserves placement but replaces mesh edits; save a copy before refreshing further mesh work.

Check clearance against the avatar from several views. Save the costume, reopen it, and check that the layer heights, preview colors, and placement remain as intended.

9. Check the cut templates

Arrange the flat shapes on paper. Print a test page at 100% / Actual Size and verify a known dimension with a ruler before cutting foam. Record stock thickness, bend, edge depth, and glue placement separately.

Result: You have a saved layered design, fitted geometry to inspect, and flat cut shapes for a physical test. Forming is geometric; it does not predict heating or foam stretch. For a missing preview or rejected layer member, see foam troubleshooting.