Cosplay armor sizing software – Cosplay Armor Fitter — fit 3D armor to your measurements, export STL and foam templates

Fit cosplay armor to your real measurements — then print it or cut it from foam

Type your tape measurements, fit any STL/OBJ armor piece to your body with a clearance check in millimetres, then export the scaled STL for printing or unfold it into foam templates with seam numbers and bevel angles (tiled A4/Letter PDF, SVG, DXF). Runs in the browser on Windows, Mac, Linux and Chromebook.

Foam templates built in. Every piece is split into foam panels and flattened with its stretch measured (kept under the limit you set). Each seam gets the same number on both edges, the bevel angle to cut and alignment ticks every 5 cm. Tiled A4/Letter PDF with a 10 cm check square, SVG and DXF for cutters.

A body made from your tape numbers. Every ring of the mannequin measures exactly the circumference you typed (chest, underbust, waist, hips, arms, legs, head) — a flat chest is allowed. Import STL/OBJ and the fit check shows in millimetres where a piece would pinch before you print.

Runs in your browser on Windows, Mac, Linux and Chromebook — nothing to install, and your models never leave your computer. A Windows app download is included.

Pro: $39 once, or $5 a month while you build. A new armor pattern opens on the 1st of every month — next: Helmet cap on 1 Nov 2026, Knee cop on 1 Dec, Gorget on 1 Jan.

Units Start from

Measure over thin clothes with a soft tape, snug but not tight. Circumferences go all the way round.

Your tape vs the model

Saved bodies

Import body file

Piece library — made from your body

Side Gap to body (mm)

Your own model (STL / OBJ)

The file is read in this browser only — it is never uploaded.

Choose STL or OBJ…

In the scene

Piece

Foam thickness mm Stretch limit

Paper Seam at creases over °

Red numbers are seams: the same number is on both pieces that join there. "/12°" = bevel each of the two edges 12°. Red ticks every 5 cm line up across a seam.

Piece

Wall for library pieces mm Printer bed × × mm

Armor Fitter Pro

Foam templates for every library piece and for your own models · DXF for laser and vinyl cutters
Fitted STL / OBJ export (keeps your file's orientation, sits on the bed)
Unlimited saved bodies — fit friends and commission clients
A new armor pattern on the 1st of every month (Helmet cap 1 Nov · Knee cop 1 Dec · Gorget 1 Jan)

Pro licence — $39 once $5 / month

The monthly plan is cancelled from your Whop account. After it ends, templates and exports for Pro pieces lock again; your saved bodies and files stay on your computer.

Windows app

The same app as a small Windows program (needs the Edge WebView2 runtime, built into Windows 10/11). It is not code-signed yet, so Windows SmartScreen asks first: "More info" → "Run anyway". On a Mac, use this page in Safari or Chrome — it is the same app.

Download for Windows (zip)

clear closer than your gap touches the body

How it works

Type your measurements (cm or inches). The mannequin is rebuilt from them; the table shows the model's circumference next to yours.

Add a piece from the library, or open your own STL/OBJ and pick the body zone. It is scaled and placed outside your body with the gap you choose; colours show where it is tight.

Make foam templates (PDF/SVG/DXF), or export the fitted STL for printing — or OBJ for Pepakura.

Clearance is measured against a mannequin made of smooth rings, not a body scan: it shows where a piece is clearly too tight, it cannot see muscles moving. Keep a gap of 6–10 mm for foam and padding.

Fit cosplay armor to your real measurements — then print it or cut it from foam

How it works

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