Commonly referred to as a Dremel, a rotary tool is a compact, handheld power tool that spins attachments at high speeds for cutting, grinding, sanding, polishing, carving, or drilling. It’s highly versatile because it can accept a wide range of bits and accessories designed for different materials and tasks. Popular in crafting, woodworking, metalworking, and repair work, a rotary tool offers precision and control for both delicate and detailed projects.
The word Dremel, like Bandaid or Kleenex is a brand name that has become almost synonymous with the tool. The technical name is a rotary tool. They are high speed, low torque handheld tools that allow you to do everything from routing to sanding, sculpting and cutting.
But we are here to discuss the use of adaptive technology in the cosplay workshop, aren’t we?
I have some nerve damage in my arm and dominant hand. While it is pretty mild as these things go, it does create some issues while working with some of the materials we use. Specifically, I have trouble cutting straight lines and bevels in foam. It’s weird. When I am not thinking about something, my movements are pretty smooth and fluid. However, when I focus and start to concentrate on something that requires precision, the tremors and twitches start.
As you can probably tell, that makes for some horrible bevels. Horrible bevels make for horrible seams. And while you can fix it after assembly, that takes a lot of time and extra work. It’s always better to make something as perfect as it can be at every step of the process to save time in the long run.
I recommend something similar to the tool pictured above. I have that EXACT one, but there are many flex shaft rotary tools on the market. The flex shaft is important because the tool end (the part you work with) is light and easy to use. It prevents muscle fatigue and let’s you work for longer. It also allows you to bet into some smaller spaces for more precise work.
My main reason for using a flex shaft is due to my nerve damage. While EVA foam is extremely durable, a rotary tool will make short work of it – chewing right into it like a velociraptor in a preschool. The normal rotary tools (like what are pictured at the top of the page) have all of the weight in your hand/in the body of the tool. When you make an error, the bit will grab and cause the tool to move. The weight of the normal rotary tool will make it worse due to its increased momentum. The flex shaft doesn’t have that weight to it and is easier to stop when it decides to run amuck.
Tips on How to Use Rotary Tools in Cosplay Builds
1. Start with the finest bit you can. Like sandpaper, the bits on rotary tools come in varying grits (roughnesses). For working with foam, I use a 600 grit or higher. You can get fine grit sleeves for the sanding drum for 10-15 cents apiece. I just got a 100 pack on amazon for $10.99.
2. Move the tool with the rotation of the bit. Pretend it is a car, and let the bit pull you along. You have a lot more control when you are moving in the same direction the bit is spinning. If you move against the motion of the bit, the tool will bite in a lot deeper. This means it will remove material a lot faster. While this can be useful for some effects, I don’t recommend it for every day usage.
3. Brace yourself. Find a way to brace your hand and rotary tool so that you don’t have any wiggle when using it.
4. Be gentle. If you push too hard, it will remove a LOT of material VERY quickly. In some cases, it can cause the tool to jump. On a personal note, the skin of a human thigh is about the same density as EVA foam. The bit will remove skin just as quickly as it does foam. I have a couple cool looking scars to prove it.
5. TAKE YOUR TIME! I will repeat it – TAKE YOUR TIME!!! Cosplay is art, and art takes time. If you rush, you will spend a lot of time fixing what you messed up. so TAKE YOUR TIME! It takes less time to go slow and get it right than it does to fix a mistake or to rebuild the piece you hurried with and ruined. I speak from experience.
Vevor flex shaft rotary tool on Amazon ($79.99)
Ryobi cordless flex shaft rotary tool at Home Depot ($89.99)
Bauer cordless flex shaft rotary tool at Harbor Freight ($34.99)
Corded (with a flex shaft attachment) at Harbor Freight ($79.99)
Corderd Ryobi flex tool (no flex shaft) at Home Depot ($69.99)
September 26, 2025
