Build
Foam hills and rivers
One sheet of insulation foam makes several hills, and a river can be made from card and gloss varnish for a few dollars.
Foam safety
Hot-wire cutting releases fumes. The Harvard GSD Fabrication Lab's procedure says: keep the wire at the lowest temperature that cuts, use local exhaust ventilation, wear safety glasses and heat-resistant gloves, use an organic-vapour respirator if you feel discomfort, and read the foam's safety data sheet. A sharp knife or a fine saw creates no fumes, but sand and cut outdoors or with a mask, because foam dust gets everywhere.
Hills
Cut the shape
Draw a rounded, irregular shape on XPS foam. Make the top flat enough to stand models on. Cut with a hot wire (see safety above) or a long sharp knife.
Bevel the edges
Slope the sides so models don't slide off. Stepped hills (two layers glued together) are easier to play on than smooth domes.
Protect the foam
Coat it in a mix of PVA, water and a little sand or tile grout. Most spray paints melt foam, so don't spray it directly.
Paint and flock
Brush on a mid-earth house-paint sample, dry-brush lighter, then glue patches of flock or static grass. Leave some earth showing.
Rivers
Cut sections
Cut straight and curved river sections from thin card or plastic sheet, all the same width, so they join in different layouts.
Banks
Glue sand along both edges for banks.
Water
Paint the middle dark green-brown, lighter towards the banks, then add several coats of gloss varnish. Flat rivers don't block movement, so agree with your opponent whether they count as difficult ground.
Woods, using the same base
Make a flat, irregular base from hardboard or thick card, texture it like a hill, and place trees loosely on top. Removable trees let you move models inside the wood.
Sources
- Harvard GSD Fabrication Lab: Hot-wire foam cutting (EPS and XPS) SOP — hot-wire safety controls
- CDC NIOSH Health Hazard Evaluation 2005-0243-3016 (hot-wire foam cutting) — health hazard evaluation of hot-wire foam cutting
Sources checked October 25, 2026. Figures are quoted as the source gives them; where sources differ we say so.