No-Stitch Superhero Baby Costume


When it comes to kids and Halloween, dressing up your little one in a handmade costume is so much fun. It’s also a great chance to let your creative juices flow freely. My son will be pushing three months, and while he’s too young to go trick-or-treating, he’s not too young to dress up! So I decided to make Oliver his first Halloween costume.

I shuffled through my arsenal of fabric and found the perfect pieces for the costume I designed in my head – a mini superhero costume.

It turned out just as I had imagined and with no stitching involved. How perfect is that?!

Take this idea and run with it. This can easily apply to bigger kids and adult costumes by applying the iron cutouts onto a plain t-shirt and tights.


Here’s how I made the no-stitch superhero costume.

What you will need:

  • White, long-sleeved onesie
  • 1/2 yard of fabric for the cape, in the color of your choice
  • 1/8 yard of fabric for the belt in color of your choice
  • 1/8 yard of metallic fabric for the hero logo (i.e. lighting bolt) design and buckle. I suggest gold or silver for this one.
  • 1/8 yard of  fabric for the “initial letter” (i.e. “O” for Oliver), in the color of your choice
  • Then you will need a spool of ribbon in the color of your choice (I went with the same color as the letter I was using)
  • Scissors
  • Steam-A-Seam iron-on adhesive paper

**Note – you will have extra scraps of fabric leftover


Draw your logo design, which for me was a lighting bolt, onto the adhesive paper. Then flip it over and trace what was drawn onto the other side of the paper.

You’ll need two cut-outs, one for the onsie and one for the cape.

Peel off the stickier side of the adhesive paper and press it flat against the piece of fabric you are working with. Cut out shape.

Peel off last piece of paper once the shape is cut out and place it firmly onto the onesie.

Do the same with the cut-out letter.

Iron on each cut out separately (follow directions for ironing on the Steam-A-Seam package). Place an extra piece of fabric over the metallic cut-outs before ironing, so the fragile fabric does not singe.

Cut length of cape to about 3 feet. Iron on the logo the same as you did for the onsie.


Starting 1 1/2 inches from the end of the cape, begin to snip a 1/4 inch cut, every 2 inches until you reach the other end of the cape.

Cut a four foot strand of ribbon and weave it through the slits in the cape.

Cape should fold accordion style after weaving ribbon through.

Using another sheet of Steam-A-Seam, draw out a belt and a buckle. For the buckle, draw a larger square, with a smaller square inside.

For the belt, measure about 1 1/2 inches in thickness and make sure the belt is as long as the width of the onsie, on one side.

Cut out the shapes.

Iron on the belt.

Then iron on the buckle (place a piece of fabric over the buckle before ironing it).

Let costume “cool” before you play dress up with your baby.

I really wanted to make a mask for this costume. I think it would be a great thing to have for a kids costume. What you can do is use an extra strip from your cape material (enough to wrap around head and tie in back) and cut out eye-holes.

Hope this inspires some of you to make your own costume this year!

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  • kelsey
    Posted October 22, 2011 at 10:49 AM | Permalink

    He is sooooo cute. What a great costume :)

  • Fran
    Posted October 23, 2011 at 1:33 PM | Permalink

    This is waaaay too cute, including the baby!

  • Janet
    Posted October 25, 2011 at 7:15 PM | Permalink

    The world’s most handsome superhero!! Adorable :)

  • Julia
    Posted November 1, 2011 at 3:50 PM | Permalink

    Super Ollie! Cute costume, cuter baby!

  • Joy
    Posted November 3, 2011 at 8:51 AM | Permalink

    What a cute idea!!!!

  • Posted October 30, 2012 at 7:39 PM | Permalink

    THANK YOU! I forgot about a Halloween potluck tomorrow at work (I am on maternity leave) and I was close to panic-mode when I found this through Pinterest! So genius! I am just painting directly on baby’s onesie & mommy’s t-shirt :) thx again!

  • Posted October 31, 2012 at 7:56 AM | Permalink

    Oh that would be so cute! Congratulations on your new little one.:)

  • Carrie
    Posted January 24, 2013 at 7:46 PM | Permalink

    Wow, very cute! I did this today, except I used iron-on velcro instead of ribbon for the cape (one part of the velcro is on the back of the shirt at the neckline, the other part is on the cape). I am just super paranoid about strings near baby’s necks. :-)

  • Posted January 25, 2013 at 8:15 AM | Permalink

    Yes, it is definitely a cape you would want to supervise at all times.

  • Corrie
    Posted January 26, 2013 at 9:47 PM | Permalink

    We loved this idea so much that we made the costume for my 3 month old and then did a modified family super hero theme for Halloween. Thanks for the tutorial.

  • Posted January 26, 2013 at 10:47 PM | Permalink

    That’s so great to hear!

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