Live hingeable plastic gluable to foam

I need to hot stamp a piece of sheet plastic to form a component part with a very flexible live hinge and hooks projecting to accept a rubber band biasing the hinge to a position.

I have access to a thermo-forming machine that will heat the plastic sheet and move it to a molding station.

Making this component via injection molding is cost prohibitive. I'm in the USA and I am producing a product that is in competition with China. Don't tell me it's useless to try 'cause by God I'm gonna Git 'er Done. To get an idea of what I need to do see the Sling Wing patent # 4,817,836. I've been using a tape hinge and stick-on picture-hanging hooks but now I need to make a one-piece part incorporating the hinge, that must have minimal folding resistance, and at least one hook large enough to accept the launching rubber band, in addition I need to glue it to Expanded Polystyrene Foam wing sections. Tough order I know but I believe in Yankee Ingenuity. "Can't be Done"replies will be ignored. I've been told polypropylene is the way but hoping one of you guys will either affirm that or have a better suggestion. Thanx, Steve Corbin