Redditor ThEflatClarinet decided to make Dick Grayson’s Nightwing for his third ever cosplay build. He made an armored version of the character using EVA foam as the primary component. Without doing a formal tally, I think EVA foam is the material that I come across most — it’s no wonder since it’s accessible, inexpensive, and versatile. ThEflatClarinet was inspired by Dynamite Webber Cosplay’s Nightwing and drafted out a design referring that ensemble. He used the following supplies:
Materials: Armor: EVA foam, Craft Foam, Barge cement, rustoleum spray paints, Bounce brand Rubberizer, cabinet liner, acrylic paints, leather rivets, velcro
Eskrima Sticks: 3/4 in. PVC, 1 in. PVC, wiring, solder, LED AV switch, Dollar Store flashlight (pulled out the LED components as well as the battery pack)
Undersuit: Design by 4neodesigns sewn and printed by zentai-zoneMask by: TigerstoneFX
You can see his sketch for the costume below, as well as a couple of in progress pics.
See the costume come together in this Imgur album.