Based on online photos and descriptions, "
Black Textural Polyester Neoprene" from Mood Fabrics seemed like the closest thing I could find. I had a chat with one of their online representatives who felt it might be a good choice for the costume. Today, I received sample swatches in black and navy. The navy version is simply called
Navy Spacer Mesh and I think the description for that one is a bit more accurate as the swatches are clearly the same fabric in two different colors (there really is no neoprene).
The outward texture is pretty much exactly what is used the shoulders and back of some of my backpacks. I don't know if it's exactly the same fabric or if it's just that layer. The inside layer is smoother. To me, the texture looks exactly like the high resolution photos from The Avengers. The material is somewhat see-through, but placing it over my skin, it looks black. It stretches about 30% in one direction and 20% in the other.
I think it's possible that there were spacer mesh and actual neoprene versions of the suit made for the film. The texture looks very smooth and rubbery in many of the action shots - quite different from what it looks like in indoor & poster shots. I have a version of the costume completed, but I used a 1mm wetsuit body along with black compression leggings instead of a one piece suit. Except for the somewhat inaccurate surface texture and some difficulties hiding a logo on the chest of the wetsuit body I used, 1mm neoprene worked really well for me. It wasn't too hot to wear indoors, although it did get sweaty inside the suit. From set photos, it's clear that at least for Age of Ultron, two piece suits were also used. There's a
photo of two stunt doubles wearing the bottom without the top.
How does the spacer mesh compare with what you have been using?
Also, I guess Yaya Han's zippered
bodysuit pattern might be a good starting point. I'm completely new to making costumes, so using a pattern seems like a good idea.
I'm writing a series of online articles on the costume I put together for Halloween (+ a few bits I did more recently). I'll post a link here when it's ready - about 80% of the writing is done, so probably end of this month or early January. The new suit isn't really part of the series I'm writing, but I'll probably mention the fabrics etc in passing and then if I make a new suit, I'll consider writing a new article about it.