DIY Shoulder Pauldron for Cosplay

Ultimate Cosplay Tutorial: Crafting Your Own Shoulder Pauldron for Cosplay (With a Dash of Fun!)

Welcome, cosplay creators! Ready to bring your medieval, warrior, or epic fantasy character to life? Today, I’m guiding you through the process of making an intricate scale armor shoulder pauldron—but hold on! You might need some advanced tools to get those fine details just right, like a Cricut machine. If you don't have a Cricut machine, have no fear. You can definitely make this by hand cutting your pieces as well.

I’m here to make this project fun and stress-free! And hey, if yours doesn’t turn out exactly like mine, THAT’S OK! The beauty of cosplay is in the customization—you can make it uniquely yours.

Before we dive into the world of hot glue guns, felt, and (let’s be honest) a little chaos, here’s a quick reminder: this is YOUR creation. I’m just giving you the foundation—you get to build the rest.

Ready? Let’s make some scale armor magic! 

Let's gather our supplies and tools:

• Several color variations of Craft Felt from The Felt Store for the "scales" (the hero of the day!)
  • I used Rayon/Viscose Craft Felt as well as some Acrylic Craft Felt, but Wool Blend or 100% Wool Craft Felt would also work great!
• 3mm Designer Felt from The Felt Store for the crossbody connection and bottom structure (you’re going to love this stuff).
• Cricut Maker Machine or sharp scissors
• Fabric dye of your choosing (because we love customization!)
  • This of course is optional.
• Thick paper (for sizing your shoulder like a true warrior)
• Tape (because we all need tape in our lives)
• Soft tape measure (for measuring your body, obviously)
• Hot glue gun (for sticking everything together like the crafty wizard you are!)
  • You can also sew the pieces together for more structural strength.
• PDF Pattern for "scales"

Downloadable PDF Pattern:

Shoulder Pauldron Scales

Step 1: Pick your colors (because a good color palette equals a good time)

For my shoulder pauldron, I picked five stunning shades from The Felt Store’s craft felt section: Rayon/Viscose Craft Felt in Yellow and Dark Green, along with a few vibrant hues from their acrylic felt sheets (pictured below).

When selecting your colors, think about balance and contrast—the right palette will give your piece that extra wow factor! ⚡️

Feel free to stick with what you see here, or—dare I say it—get creative! If you want to add some depth and richness, dye your felt! I soaked my felt in blue dye for a solid 2 hours. Why? Because it gives that cool, slightly weathered look and adds to the custom look. Once dyed, let your felt dry flat on a table. 

Once your felt sheets are dry, it's time to prep your Cricut Maker machine!  Load it up with a rotary blade (because we’re fancy like that) and use the template below to cut your felt pieces.

Start by cutting five sheets in different colors—this will give you the perfect mix for your top layer of scales! 

Need a little extra help? Check out this tutorial on how to prep your Cricut mat for cutting felt.

Step 2: Creating the base pattern (let’s get structural)

Now it’s time to build the foundation of your epic pauldron. Follow these steps carefully:

1. Print out the template and choose a scale that fits your shoulder. Don’t be shy—customize the size until it feels just right! After all, this is your epic pauldron, so make it work for you.

2. Lay your printed template flat and start assembling the cut pieces from your Cricut to form the top layer of your pauldron. Make sure the edges overhang the paper in every direction while keeping the seam area open—you’ll connect the ridge later.

Don’t worry, this extra overhang will give your pauldron a bold, three-dimensional look! Plus, you get to choose which side to showcase for the best effect.

3. To create the top ridge, (giving your pauldron its signature shape) insert a small piece between each row to connect the gaps along the top ridge. This will help reinforce the structure and add that bold, dimensional look.

Once assembled, set it aside—you’ll come back to it in the next phase!

4. Time to create the foundation of your pauldron! Grab your chosen color of 3mm Designer Felt from The Felt Store for the base. Using your paper template, trace out the size you need.

Then, sew or hot glue the felt together at the seam—this will form the sturdy structure underneath, giving your pauldron its sleek, polished look.

5. Now, it’s time to bring it all together by attaching the top and bottom layers! Glue or sew your top skin onto the felt base, depending on your preferred method and how sturdy you want it to be.

For crisp, clean edges, tuck the overhanging pieces underneath your felt base before securing them. This will give your pauldron a polished, professional finish!

You’ve now got your base structure, and your main skin glued together. Take a moment to admire your work… but we’re not done yet!

Step 3: Crossbody connection

Now, let’s figure out how to wear this thing! Using a soft tape measure, find out how long you need your connections to fit across your body. The template has some guidelines to help you adjust it to your measurements. You want the shoulder pauldron to sit comfortably but securely. Don’t make it too tight, or you might find yourself in a bind—like, "Oh no, where’s my trusty hot glue gun!" kinda thing

Once you’ve got the length, cut your Designer Felt, glue or sew the pieces in place, and voilà—you’re done!

As always, my friend, the beauty of crafting is in the details. You might find yourself adding some extra layers, decorations, or materials to truly make this shoulder pauldron your own. After all, what’s cosplay without a little personal flair?

Share your own unique variations and let's keep the inspiration flowing. Feel free to share your creations with us on social media by tagging @The_Felt_Store and @AKKIKA on Instagram.

Happy crafting and may your epic cosplay battles be ever victorious!

Bonus Fun Fact: Shoulder pauldrons were once used in medieval armor to protect the wearer’s shoulders from sword strikes. Today, they’re mostly for looking awesome at conventions and intimidating your opponents in games like Dungeons & Dragons.

Now go forth and create—with style!