Here's a Dark Knight version batman mask made of mostly duct tape.
It's fairly rough, but maybe it'll inspire somebody. Enjoy!
What you'll need:
To start, I laid out lots of strips of duct tape on my cutting mat, and sliced them into various sized smaller strips. Using a plastic grocery bag to protect my head, I started putting tape all over my head to get my personal head-shape. I trimmed off extra plastic as I went. My head was sweating like crazy, as plastic and duct tape don't breath very well...
Added strips of tape to cover nose and cheeks, leaving eye holes.
I used a sharpie to draw on the mask (while it was still on) where to cut out to make room for a nose piece. This was made through trial and error with triangular pieces of cardboard folded down the middle until I got one that fit comfortably over my nose. Another triangular piece was taped across the bottom to make it rigid. Then the nose piece was taped into place.
Once the nose piece was in place, I stuffed the entire thing full of wadded grocery bags and put a few pieces of tape across the chin area to keep the whole thing in a solid, head shape.
At this point I had to just sculpt till I had results I could live with. I used wadded newspaper wrapped in masking tape to get the shapes I needed, and then taped them on. Using a snap-blade style utility knife with a sharp blade fully extended, I trimmed off extra bulk as needed.
I had to put about a six-inch slice in the back of the mask to get it on and off.
The antennae were made of cardboard with newspaper on the inside to add bulk.