This is a more complex form of fursuit, usually selected for better definition of body shape. These fursuits are created by attaching carved foam to a unitard or close-fitting undersuit; this "foam buildup" creates a new shape on top of the wearer's body. A layer of fur is then attached to the foam to complete the suit.

Advantages and Disadvantages

This style of fursuit design's advantage is that it may produce much more realistic/inhuman body shapes. Whereas a sewn suit must be hung on a human frame, this style of suit uses foam padding attached to a skin-tight suit to effectively redefine the surface beneath the fur. If properly designed, the movement of the foam can even give the illusion of muscles beneath a layer of fur. Usually, the fur is glued directly to the foam padding; the edges of each fur piece need to be sewn together, though, to prevent the seams from showing as the suit flexes. It is also possible to sew the outer fur layer so that it fits tightly over the foam layer. This second technique is much more labor intensive because it combines the difficulties of foam-buildup and sewn-suit design, but it allows the fur to slide a little over the foam, giving the illusion of an animal's hide shifting over a muscle layer.

There are many disadvantages which must be accepted in exchange for this newfound realism. First, this style of costume is one of the more difficult approaches to fursuiting. Secondly, since the costume is skin-tight, it fits only one person (or people of almost identical stature). Also, because the suit is worn against the skin, this style of fursuit can be quite hot if there's extensive foam padding (think of it as skin-tight insulation).

Construction

Construction begins by purchasing (or making) a form-fitting lycra bodysuit. This becomes the inner lining of the costume. In order to make sure the costume is properly fitted to the wearer, the suit must be worn during construction or a dummy of precise proportions must be substituted. (See the page on Duct Tape Dummies for a cheap way to get a full-body sewing dummy with your proportions.)

Pieces of foam must be carved to create the padding for the suit. Foam may be purchased from fabric shops in sheets of varying thicknesses; for larger chunks of foam, try an upholstery shop. Foams of different densities may be used, depending on how soft you want the suit to be and how much flexibility is required at that location. After the pieces are cut to satisfaction (use scissors or an electric carving knife), they are glued directly to the bodysuit.

For Widge, my first fursuit, I used hot glue. While this is possible, given a high heat tolerance, it is certainly not the recommended method. (Hey, at the time, I didn't know any better!) Instead, look into using aerosol glue products, like 3M Super 77. But you can use any glue that doesn't release a lot of heat as it cures, really. Glues that remain semi-flexible after they are dried are preferred.

After all of the foam is applied, the suit is ready to be furred. Usually, the fur is applied directly to the foam layer with aerosol or hot glue. To apply the fur in this manner, cut pieces to an approximate shape. Glue the center of the piece to the foam or undersuit; allow a little time for it the glue to set it in place. Trim the edges of the piece so that the seams fall where you want them. Then you can glue and press the entire periphery of the piece. For extra security and durability, you can hand sew the fur pieces edge-to-edge with a simple stitch. (I always recommend you take the extra time to sew the pieces; it's worth it!)

For costumes which require more sophisticated movement of the fur and greater realism, the fur layer can be sewn separately. This is similar to the procedure for creating a sewn suit, including the difficulties of tailoring a new pattern.

Once the fur has been applied (in numerous little bits), secure any loose edges. Particularly pay attention to fur edges on the outsides of joints (e.g. the elbows and knees), as this area is prone to stretching. If the fur pieces pull apart visibly when flexing, take the suit off and sew the fur pieces edge-to-edge using a heavy (upholstery) thread. Now the fur cannot pull apart and the tension instead compresses the foam padding around that joint. Once all such details have been taken care of, the suit is complete!