I was commissioned by a customer to make a Young Justice Robin belt. After designing a template, I cut the shapes out of 3 and 5mm thick eva foam sheets. For the round buckle, I found a toy plastic ball from the local craft store and cut it in half (it was hallow and easy to cut), and then used a heat gun to stretch a layer of foam sheet over the ball and glued the edges of the foam to a base layer of foam under the ball. Everything was hand painted with acrylic paint. The pouches attach to the belt with chicago screws, and a length of polypropylene webbing was glued to the back of the belt for extra durability. A velcro strap was made to secure the belt from the back, and more webbing was used to make the baton straps.
I also made the customer an alternative set of much slimmer, decorative pouches that could be swapped in and worn when he didn’t need to hold anything in the belt.
The template for the belt is available here.