if you've tried the craft foam, next soft things to try are old wetsuits and mouse pads.

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My Blog - http://leegoocrap.blogspot.com

Back when the Scott clip-on bar first came out, it didn't have any pads. It was a couple years before Lemond first used them in the TdF.... Anyway, I had a set then, and made my own pads. I cut 4" ABS conduit in quarter length-wise, about 4" long, rounded the corners. I pop-riveted some steel lumber strapping onto the outside at an angle (flat part of the pop-rivet towards the inside), then used some blue-foam camping pad and glued that to the inside. Using regular pipe clamps to hold them onto the handlebar. Worked great, held up fairly well, cost almost nothing, and were some of the first arm pads on the PacNW tri scene.

Now, I'd go the 3D-printing route...

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Some are born to move the world to live their fantasies...

https://triomultisport.com/
http://www.mjolnircycles.com/

Craft foam. Sells in 8 x 11 sheets. Feels flimsy as one sheet, but feels perfect with 4-5 of them glued together into a stack. Cut with scissors to shape.

I used 'Shoe goo' to glue them together.

I also used velcro tape to stick them onto my aerobar pad holders. Worked great, easy to replace if the sweat starts to reduce the sticking of the tape to the pad holder.

Used these for over 2 years no problem.

I think evazote would be a great material for armpads. If only the MEC pads weren't yellow I'd try.