Another cosplayer! Awesome. I make props and use lasers in my build process. Im not sure if youre familiar with evil ted or punished props, but they are the guys who invented the use of EVA foam for cosplay and have a ton of good tutorials on it on youtube, and bill doran (punished props) has a lot of ebooks out that are must-haves for foam work called the foamsmith books: (books by kamui and volpin are also highly recommended)
http://punishedprops.com/product-category/ref-mats/
This is one of the videos that I send to everyone, as it has a ton of good tips for those new to EVA crafting:
Im not sure your skill level or experience, but I figured Id share regardless. Happy to help if you have any questions
I recently posted a helmet build Zer0 Helmet Build (detailed post) - #44 by takitus. check it out!