DIY Kids Toy Story Alien Costumes

I may be a crafty gal but I have no skills at sewing. Making a homemade Halloween costume is sometimes a challenge for me. Thankfully, I came up with a way to create cute homemade Disney Toy Story Alien costumes with my usual craft tools and supplies. No sewing required. I used felt, scissors, and a hot glue gun. The truly homemade parts of the costumes are the Pizza Planet logos, eyes, antennae and ears.


My family recently came home from a magical Walt Disney World vacation. We love visiting during the fall and especially enjoy attending the Mickey’s Not So Scary Halloween Party at the Magic Kingdom. We wanted to dress up in Disney themed costumes for the party. The kids all agreed to be the cute little aliens from the Toy Story movies.

My challenge was to not buy a pre-made costume. The costumes needed to be comfortable, stylish, and simple. They also needed to be easy to pack in a suitcase.

For my two daughters, I wanted it to be girly. Instead of wearing long blue pants or a blue jumpsuit,  I bought blue skirts and short sleeve shirts from Justice (on sale). Also, they wore lime green headbands with alien eyes attached.

For my son, I bought a blue short sleeve shirt from Old Navy and shorts from Target. We chose shorts instead of pants because of the Florida warm weather. The alien head was made using a lime green hat with eyes, antennae, and ears attached.

The materials I used to make the Pizza Planet logos are blue felt, yellow felt, orange felt, red felt, gray felt, green felt, scissors, hot glue gun and hot glue gun sticks.


I used an image of a Pizza Planet logo as my guide. I found the image on the Toy Story website. I tried to make the number and placement of each topping exact.


First, I cut out a circle from the blue felt. I used a can as my circle template.  You could use any circle as a template. I used the same can plus a smaller can to make my template for the orange felt circle outline that goes around the blue circle. I cut out a planet ring from the yellow felt. I cut out four small red felt circles for the pepperoni. I cut out three tiny mushroom from the grey felt. I cut of four little pieces of green felt.


I glued all the pieces together. First the orange felt outline on the blue circle. The yellow planet ring on and around the blue circle. Finally, I glued on the pizza toppings.


I attached the Pizza Planet logos to the blue shirts using a safety pin. I also stitched a small portion of the top and bottom of the logo with needle and thread to make it more secure.

The materials I used to make the alien headbands are lime green headbands, white felt, black felt, scissors, hot glue gun and hot glue gun sticks.

The materials I used to make the alien hat are a lime green hat, white felt, black felt, lime green felt, lime green pipe cleaner, scissors, hot glue gun and hot glue gun sticks.

For the alien eyes, I cut out white felt circles. I then cut out smaller black circles. I glued each black felt circle on top of a white circle. I glued three eyes each on the lime green hat and the lime green headbands.


For the hat antennae, I bent and shaped the top of a lime green pipe cleaner into a small ball. The rest of the pipe cleaner was bent and glued to the top of the lime green hat. I cut out two lime green felt ears and glued to the sides of the hat.


My husband and I also got into the costume fun. We dressed as Mr. and Mrs. Potato Head. I purchased the Mr. and Mrs. Potato Head costumes.


My family and I had a fun time dressing up in Disney Toy Story themed costumes for the Mickey’s Not So Scary Halloween party. It was an amazing party. There’s nothing like trick-or-treating at the Magic Kingdom.

Have you made any Halloween costumes?

Happy Halloween!

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  1. Where did you get the lime green baseball cap at? Its kind of hard to find this hat anywhere. Thanks!

  2. Where did you find the hat?

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