Repurpose common items. If the script calls for a specialty item, such as a phone onboard a space ship, consider how an everyday telephone can be modified to fit the needs of the production. With paint, wires and hot glue, you could transform an old telephone into a space aged communication device. Remember that the audience is at a distance and small details might be disguised, so this gives you even more leeway.
Use EPS foam to create props. Commonly known as Styrofoam, this versatile material can be bought in various forms, including huge sheets used for insulation. These large pieces can be made into stone pathways, walls and other set pieces, while smaller pieces of EPS can be shaved, cut, shaped and molded into any form imaginable. You can even created a natural pitted surface by applying spray paint or paint thinner to the foam. These solvents cause the foam to dissolve and leaves behind interesting textures and patterns. Use the solvents slowly to control the dissolving process. Paint your item using water based paints.
Use fabric to create props. Some items called for in a play or musical script are used as props but could also be considered costume pieces. Get creative in the sewing room with fabric, glue and embellishments. You can even use quilt batting or polyester fiber fill to create soft sculptures for use as props. Make sure you are working in conjunction with the costume designer to avoid conflicts between prop design and costume design.
Borrow or rent props. If something you need is very specific to a particular show, locate another theater company that has recently performed the play or musical and ask to borrow the prop they used. Sometimes they will make it available for a rental fee. Get permission to modify it and make it your own. This allows you to make it right for the style of your production, but not have to start from scratch.