Bevel

A bevel is an angled cut or shaped edge on a material, commonly used in cosplay to give foam armour pieces a refined, faceted look instead of a blunt flat edge.

When you cut straight through a sheet of EVA foam, the resulting edge is a flat 90-degree wall. A bevel changes that by slicing or sanding the edge at an angle, so two adjoining surfaces meet at something other than a right angle. This gives armour panels a sharper, more sculpted silhouette and helps pieces sit flush against each other when they are meant to overlap or join at a seam. Bevelling is most often done with a sharp craft knife held at a consistent angle, or by carefully running the edge across a sanding block or rotary tool. Keeping your blade fresh matters more than most beginners expect, because a dull blade drags and tears foam rather than slicing cleanly. Always cut away from your fingers and on a proper cutting mat. If you use a rotary or power sanding tool, wear eye protection and a dust mask or respirator, since fine foam dust should not be inhaled. Younger makers should work with an experienced adult when using bladed or power tools.