Horns — EVA and Foam Clay
The simplest approach to horns uses EVA foam rolled into a cone shape and sealed. For more organic-looking horns with taper and curve, foam clay is superior — sculpt while wet, allow to air-dry fully, then sand, prime, and paint. Foam clay horns can be attached to a wig using headband wire or bobby pins, or directly to the head with spirit gum for a more secure hold. Worbla over an EVA core works for harder-edged horn designs that need durability.
Ears — Worbla and Foam
Elf, animal, and fantasy ears are most convincingly made from Worbla shaped to the specific ear design, finished to match the skin tone, and attached either to a headband (hidden by hair) or directly to the ear with spirit gum and pros-aide adhesive. The attachment method depends on the weight and size of the ear piece — small pointed elf ears can be spirit-gummed directly; larger or heavier pieces need a supported attachment.
Horns in Wigs
For characters who wear horns as part of their design (not as prosthetics), integrating horns into a styled wig produces the most convincing result. Wire forms inserted into the wig base, with foam or Worbla horns built over them, create horns that move naturally with the wig and don't require separate attachment. Secure with epoxy or strong adhesive at the wire-to-wig junction.
Finishing for Skin-Match
Fantasy features that are meant to look like the character's actual anatomy (ears, horns that are 'part of' the character) need to be finished in the correct character colour, not necessarily skin tone. Features meant to be prosthetics worn by the cosplayer need to be matched to the wearer's skin tone with body paint or foundation, then sealed with setting spray for durability through a convention day.