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5

The mats are common, as you suggest and are composed of EVA foam. Almost every source I've found involves textured surfaces and interlocking edges. This is not universal. Cosplay costume makers use this material for creating various components of costumes, including masks and armor. My brief search returned un-textured foam in 0.25" thickness (6.35 mm) ...


4

What you're looking for is foam interfacing (Pellon Flex Foam, Annie's Soft & Stable, Bosal In-r-Form, etc). This is a soft foam material generally about 1/4" (6mm) thick, designed to be sewn into projects like bags, totes, and hats to provide them with a stable structure while still allowing them to flex--it's meant for exactly your intended use. ...


3

If the only problem with the craft foam is the floppiness, you may have luck with high-density EVA foam. Depending on where you're located, there are a number of online cosplay suppliers who have it available, and I know that TNT Cosplay, at the very least, provides free samples of their foam. Speaking from experience, high density 2mm EVA (the thickness of ...


1

A similar material is used for cheap camping mattresses. It's usually blue. Search for "blue foam camping pad" or "sleeping pad" or "camping mattress" or "yoga mat" etc. Not sure how it compares in terms of price. Make sure you're buying the smooth kind that can be rolled up; there's also a textured kind that folds up ...


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