I make "no sew" costumes for DS. Last year, he was Buzz Lightyear.
What I did is sooo easy! I bought a white sweatsuit and, using felt, cut out all the decorations that go on Buzz's uniform. Thankfully, ds has a ton of Buzz stuff, so I took one of the figurines and copied it all down. Most of the stuff I had to free-hand, but it was quite simple. When I finished cutting everything out, I used the iron-on fusible web stuff to get the felt items to stick onto the sweatsuit! I made him the purple "hat" and the Buzz belt. The flap that Buzz lifts to talk to Star Command is even there ... all made w/felt!
The outfit is darling, he wears it ALL the time (it's a warm, June day and he has it on as I type this!) and it's been the best costume ever!!! I love that he likes to wear it even though halloween is over! He even wore the costume to Disney's Toy Story On Ice and got a lot of compliments on it from the people running the show! This Halloween, he wants to be a Power Ranger, so I will do something similar w/a sweatsuit, fusible web and felt!
If I can find a photo, I will scan it in! Your pal, Jessie