I was commissioned to make the Arkham City version of Red Robin’s utility belt. It was made of 3 and 5mm foam sheets. To get the curved edges and inner circle on the buckle I built up layers of foam in those shapes and then glued a thin, flat sheet of foam on top and stretched it over the shapes so they would show through. The belt was backed with polypropylene webbing and the pouches were attached using chicago screws and washers.
The template I made for the belt is available here.