My nephew requested an astronaut costume for Halloween this year. (It went well with his older brother’s sun costume!) I used a pattern; the material is vinyl. The patches were ordered off of the internet.
Total Spent: $25
For this costume, I made a simple one piece jumpsuit. I found some clipart and made the patches for "NASA" and transferred them to iron on paper.
For the helmet, I used a plastic pumpkin and spray painted it white. I used a dremel tool to cut out the front for the face. I added some reflectors (this is also great for seeing the child at night).
For the rocket booster backpack of the costume I used some shiny Capri pants I got at a garage sale and cut the legs off and sewed the end shut and stuffed it. I made two and attached them to the belt with more reflectors. Wow, looks like he could walk on the moon with his costume!