Bat-fan01 wrote: ↑Thu Apr 08, 2021 6:36 am
Personally I don’t think felt is the good idea after what happened to you, but I don’t know what fabric could fit. I don’t know about Robin, I never got informed about his costume.
Felt, of course, does not fray when cut, so it worked for cosplay.
After creating my Robin costume - and being disappointed with several attempts to do a similarly-sized "Fantastic Four" emblem while avoiding felt - Marvel Comics released numerous designs of round, iron-on, washable character patches, each embroidered around the perimeter with a contrasting colour. They also did a "4" logo, in the perfect size for my Mr Fantastic costume, and I simply covered up their copyright fine-print with a white marker.
So that style of patch would work for Robin. Plain round black, embroidered around the edge with black, with the yellow iron-on or embroidered "R". Maybe I should find someone with a computerized embroidery attachment on their sewing machine?