How to Make a Toy Story Alien Costume DIY? | Three-Eyed Green Alien

A Toy Story Alien DIY costume pairs a green headpiece with three eyes and antennae with a blue outfit and Pizza Planet details

For the Pixar fan who wants to become the three-eyed green alien, the costume comes down to two pieces: a headpiece that sells the look and a blue outfit that completes it. The whole project can come in comfortably under $10 with craft foam, felt, and hot glue. Here’s the fastest route to a costume that reads as “the claw’s favorite” from across the room.

The Alien Headpiece: Felt, Foam, and Three Eyes

Start with the headpiece, since it’s the part people recognize first. A green beanie works well for a snug fit; a headband made from a foam sheet works too and costs less. Whichever base you choose, fit it on the wearer before gluing anything so the ears and antenna sit correctly.

For the eyes, you have two solid options:

• Styrofoam balls: Slice about a third off each of three balls so they sit flat, paint them green, then hot-glue on pupils cut from black felt and small white felt shines. Glue the finished eyes to the front of the beanie.
• Giant googly eyes: Attach three wiggly eyes directly to the headband front. One tutorial recommends hot glue over adhesive backing, since sticky-backed eyes won’t hold on a child’s active headband.

For ears, cut two teardrop shapes from felt or flexible foam and glue one to each side. The antenna uses a fourth styrofoam ball painted green, plus a green pipe cleaner shaped into a spiral or loop and hot-glued to the top of the beanie. If you’re using a foam headband, cut the antenna from green foam and cardboard, then attach it at the midpoint on the inside back so it balances.

Building the Blue Outfit and Pizza Planet Logo

The body is a royal blue shirt dress or a giant blue T-shirt paired with blue jeans. Green tights, leggings, or socks add the alien skin tone below. A dark navy sash at the waist and a purple bead necklace complete the ensemble, and royal blue shoes finish the look.

The Pizza Planet logo on the chest is the detail that sells it. Cut the emblem from three vinyl colors—yellow for the large oval, red for the pepperoni, and orange for the large circle and mushrooms—then layer them onto the shirt. Felt or cardboard work as substitutes if vinyl isn’t on hand.

Assembly Order and Common Mistakes

Make the headpiece first, then add the blue clothing base, and finish with the Pizza Planet emblem and green accessories. This order lets you adjust the headpiece while the outfit is still simple to change.

The most common mistake is skipping the fit check. Place the headband or beanie on the wearer before attaching ears, antenna, or Velcro. Child head sizes vary widely, and a headpiece that fits wrong will slip or sit crooked. One tutorial specifically advises marking ear and Velcro placement while the headpiece is on the child.

Hot glue is involved in nearly every step here, and it burns skin quickly. Work with a low-temp gun where possible and keep a bowl of cold water nearby. Use generous glue on the eyes—they’re the focal point, and loose ones ruin the effect.

For a complete list of ready-made options if crafting isn’t your thing, check our roundup of the best alien Toy Story costume picks.

Cost and Time Breakdown

The project costs under $10 if you build from foam sheets, felt, and basic supplies. Most tutorials estimate a single evening of work, with the headpiece taking the bulk of the time. Country Living’s DIY alien costume guide offers a detailed photo walkthrough of the beanie-and-styrofoam method if you want a visual reference.

Skip the expensive store-bought version. A homemade alien costume looks better, fits better, and costs a fraction of the price—plus you’ll have bragging rights when someone asks where you got it.