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I'd go the leather route.
-Get yourself some thick veg-tan leather from a craft shop or leather shop.
-Make yourself a template out of cardboard, trace and cut the leather with a boxcutter.
-Saturate the leather with water to mold it to your desired shape.
-Once dried, do some finishing touches like punching holes or dying it.
-Then once its all done, dip it into some melted paraffin wax to seal it.
Leather treated in this way can be as stiff and flexible as the hard abs used on most masks. Check out some utube videos on knife sheath making.
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