Flaps are used for paper files to join pieces, so they're not quite as necessary for foam One of the perks with using foam helmets is that they're durable and don't require things like resin or fiberglass, so they won't be heavy or too fragile if you drop it and no working with toxic fumes. You can also make detail pieces using craft foam, saves a lot of fuss compared to the paper method but it's just my personal preference.Ahh thanks for that. I wanna do my Hellcat helmet but it's also a hi-res file so there's waaayyy too many tiny pieces to realistically cut out and craft. So the main things for converting to foam are just joining more faces and removing flaps? Sounds surprisingly easy haha (thought I'm sure it won't be lol) It's getting to the point where I'm tempted to recreate the helmet by kind of tracing over it in sketchup or whatever in order to simplify it for unfolding.
Unfolding would probably be the trickiest part for the Hellcat, for me at least, as I once tried unfolding an Enforcer helmet and failed miserably at the tiny detail pieces. If you could find someone who is really good at unfolding then you could convert their file to foam. Otherwise give it a try! Separate pieces into organised sections like the top, sides, front and back. I can't give the most sound advice on it as I'm still a novice but I wish you the best of luck with it!