We'll be making the patterns available as soon as we can. We won't be making costumes, just providing the patterns at this point.
The batman cowl shell is made from fiberglass. It's very thin. Approx 1/16" at it's thickest. I don't see why you couldn't use buckram for a child's costume. I frankly hate working in fiberglass!
Yes, the costumes we are wearing in the photo are the originals, not replicas. The original batman cowl has faded to that berry purple color. The rest of the suit is fading to purple too except for the cape. It's silk and still looks great.