Sculpt, Spook, and Save: How to Use XPS Foam for Killer Halloween Décor!

Sculpt, Spook, and Save: How to Use XPS Foam for Killer Halloween Décor!

Sculpt, Spook, and Save: How to Use XPS Foam for Killer Halloween Décor!

Halloween is around the corner, and what better way to bring some frightful delight to your home than creating your own eerie decorations? Whether you want to make a chilling tombstone or a ghastly haunted house, XPS foam (Extruded Polystyrene) is your perfect crafting companion. Why? Because it's lightweight, easy to carve, and eerily affordable! But first—what exactly is XPS foam, and why should you pick it over other materials for your next spooky project?

What is XPS Foam?

Imagine Styrofoam’s cooler cousin that hits the gym: XPS foam is denser, smoother, and more durable. It’s commonly used in construction, but crafty people (like us!) have realized its potential for epic Halloween builds. You can find XPS foam at home improvement stores, often sold as insulation sheets—bonus, the sheets are HUGE, giving you plenty of material to play with.

So, grab your tools, summon your creative spirits, and let’s dive into some wicked ways to use XPS foam for Halloween decorations!

1. Creating Cursed Tombstones

Nothing says “haunted yard” like a graveyard full of creepy tombstones. Here’s a simple way to get started:

  • Step 1: Draw your design. Use a marker to outline your tombstone shape directly on the XPS sheet. Go wild—make it pointy, cracked, or jagged. Remember, perfection is for the living!

  • Step 2: Cut it out. Use a utility knife or hot wire foam cutter (if you’ve got one). Keep your cuts slow and steady for precision.

  • Step 3: Add a cracked texture. Grab a ball of crumpled aluminium foil and roll it over the surface. This adds a stone-like texture, perfect for that “ancient grave” look.

  • Step 4: Carve your epitaph. With a Dremel or even a basic box cutter, etch your spooky messages: “Here Lies Dracula” or “RIP, Open WiFi Network.”

  • Step 5: Paint and distress. Use grey, black, and a hint of moss green acrylic paint. Apply darker shades in crevices and add dry-brushed highlights to accentuate the details. Finish with a light mist of watered-down black paint for that grimy, weathered effect.

2. Haunted House Miniatures

Who needs a dollhouse when you can make your own mini haunted mansion?

  • Step 1: Create the structure. Cut out your house's walls and roof panels using an XPS foam sheet. Glue them together with foam adhesive (hot glue can work but may melt the foam).

  • Step 2: Detail with windows and doors. Using a hobby knife, carve out windows and doors—don’t worry if they’re a bit uneven. It adds to the spooky charm!

  • Step 3: Texturize the walls. Roll a stone-patterned roller or carve small bricks by hand. For wood textures, lightly drag a wire brush across the foam.

  • Step 4: Paint it eerie. Start with a black base coat, then layer on dark purples, blues, and greens. Highlight edges and window frames with lighter shades to make the house pop under low-light conditions.

  • Step 5: Accessorize! Add tiny ghost figures, LED tea lights, or wisps of cotton batting “fog” for that haunting effect.

3. Wicked Wall Plaques

If you’re short on space but still want a big impact, create some hanging wall plaques:

  • Step 1: Choose your design. Sketch a monstrous face, spooky crest, or even a creepy warning sign (“Beware the Foam Fiend”).

  • Step 2: Sculpt the features. Cut out the base plaque shape and add 3D elements using foam scraps. Stack layers for depth and carve with a craft knife.

  • Step 3: Add detail with clay. For fine details like teeth, eyes, or intricate patterns, add lightweight air-dry clay over your foam base. XPS is rigid enough to handle clay without warping.

  • Step 4: Paint for dramatic effect. Go bold—use metallic paints for a cursed relic look, or neon colours under a black light to really make it pop.

Pro Tips for Working with XPS Foam:

  • Seal the foam before painting using a Mod Podge layer or watered-down PVA glue. This prevents your paints from soaking in too much and ensures a smooth finish.
  • Use proper ventilation when cutting or sanding. XPS foam can release particles that are best kept out of your lungs—no one wants a haunted respiratory system!
  • Check for melting issues if you’re using hot glue or certain spray paints. Always test a small patch first. Nobody wants a decoration that looks like it got zapped by a ghostbuster’s ray.

Why XPS Foam for Halloween?

Because it’s versatile, inexpensive, and—let’s face it—super fun to work with. You can carve it, shape it, glue it, and paint it to your heart’s content. Plus, when you’re tired of one look, you can modify your pieces without a complete redo.

So, this Halloween, ditch the flimsy plastic props and conjure up some durable, DIY foam décor that’ll give your neighbours chills for years to come. Happy haunting!


If you’re looking for premium XPS foam sheets or carving tools to bring your ghastly creations to life, visit hobbyfoamsupplies.com.au! We’ve got everything you need to make this Halloween your most haunting yet.

Back to blog