While I'm ready for a new approach to the suit, and was aware of the issues with the neck/cowl, the black foam armor never really bothered me. I never felt that it was really that restrictive in the film universe just because the real life actors said that they had trouble moving in it. Anyone who has worn a Batsuit knows that there are challenges involved just in wearing that cowl and a long cape, let alone moving around in boots and any kind of armored plating or padding. I think that we saw quite clearly with the new suit in THE DARK KNIGHT that more flexible armor doesn't necessarily make for a faster or more elaborately choreographed Batman.
I always felt that the actors in BATMAN and BATMAN RETURNS moved quite well and with relatively good speed all things considered, they were just utilizing a less flashy style of fight choreography, which most action movies in the late 80's and 90's did compared to today's films anyway. The idea was always is that it was lightweight, flexible, advanced form of body armor, and I've always seen it as such. I don't know, it requires a bit of suspension of disbelief and imagination, but it always worked for me. I think people have always made a bit too much of how "cumbersome" and bulky it is.