Our MOPS group decided to make some superhero masks to go in our Operation Christmas Child boxes, so the first step was to find an easy template to use. I searched online and found some basic templates here: http://www.firstpalette.com/Craft_themes/Wearables/superheromask/superheromask.html
We used felt to make them a bit sturdier than paper- and to double up that sturdiness as well as offer 2 masks in one, we made them double sided, so the recipient could change around their look. I used my Cropadile punch/setter to make holes for the elastic. We also decided on elastic rather than ribbon or cording to tie, because then they didn't need to have to tie them, or need help. They could just start playing.
On this design, I cut out the center part of the mask template and traced on another color of felt for contrast. For the lightning bolts and stars, I just looked up some clip art and honestly- I traced on a piece of paper right there from my computer screen. I cut that out and glued it to cardstock, then used the star or lightning bolt to trace around as I had the masks.
These are also double sided - oh, just in case you're wondering, I cut out the entire mask piece first, then used the center from a second template that I'd cut out, to add a contrasting color. I used my hot glue gun to glue everything together. They came together pretty quickly, and you can personalize them to your little superhero- my daughters even wanted some- so don't feel limited to boys, by any means- make hearts, flowers, glitter glue, ribbons... There you have it, some basic superhero masks. Oh, and I bought the felt by the yard at Jo-Ann's- on sale, they have a lot of color options- and depending on how many you want to make (think birthday party, etc), it might be more cost effective to buy 1/2 a yard or so of your main colors. Happy mask making!