As i had tried to create the bear's head previously with the same method but using cardboard i think that is was a good way of creating the basic structure of the head as it make it light weight but the problem with using cardboard is that when it is cut quite thinly it bends easily so would not have worked well for the structure. To solve this problem i used gray board instead which is still really light but is more solid than card board as it doesn't have the gaps in the middle of it which makes it a lot stronger and stopped the pieces from bending.
As it was only a test of if it would work i only constructed the nose of the bear, once i had created the basic structure of it i then began to cover it with bits of foam that i cut of a camping mat. The foam material from the mat works quite well as is is soft enough that it can easily be worked with and used to construct around the structure but not to soft that it doesn't keep its shape. The material also works well for creating the puppet as it is really light so that when the puppet is fully constructed it won't be very heavy at all so it will be easy to hold and use one on stage. I think that the only problem with the material is that its not that good at getting curved shapes with out cut up smaller pieces of the foam to get the right shape so you end up with lots of little gaps once its finished. This isn't a huge problem as they are not that visible from a distance but i probably would need to fill the gaps with some thing either put a thin piece of something over the gaps or cover the whole thing with something.
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