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Artist Andy Smith’s Hello Kitty and Pikachu samurai armor were handmade wearable costume projects, not documented step-by-step plans. In the 2014 Pikachu build, reported materials included a hard hat, ears taken from a Pikachu plush, plastic garbage cans for armor plates, and Wonderflex for the face mask. The available features do not give a complete pattern, measurements, or cost, but they offer a useful starting point for understanding the builds and planning a similar costume.
What are the Hello Kitty and Pikachu samurai armor projects?
They are character-inspired samurai armor costumes made by artist Andy Smith. Make: featured both projects on August 8, 2014, and Adafruit’s report on the Pikachu build describes some of its construction materials. The reporting says Smith had already made Hello Kitty samurai armor before continuing the idea with Pikachu.
These are visual references, not complete tutorials: the articles do not supply a printable pattern, dimensions, a full assembly sequence, or a materials budget. Treat the reported construction details as clues, not a ready-to-follow build specification.
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What materials did the Pikachu armor use?
Adafruit’s 2014 report identifies four elements of Smith’s Pikachu costume:
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- Hard hat: used as the helmet base.
- Pikachu plush ears: removed from a plush and incorporated into the helmet.
- Plastic garbage cans: used to make armor plates.
- Wonderflex: used for the face mask.
The article does not establish the exact type or thickness of plastic, how the plates were attached, or what other fasteners and finishing materials were used. It also does not say Smith used EVA foam.
How can you plan a similar wearable armor build?
A separate samurai armor kit maker describes a general workflow that can help organize a costume project. This is that maker’s process, not a verified account of Smith’s construction.
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- Choose a size and materials. Decide what parts need to fit the wearer and select suitable sheet material, fabric, cords, and decorative details.
- Cut pieces from patterns. The kit maker describes cutting plastic to paper patterns with a craft cutter. Its listed kit materials include patterns, plastic, fabric, cords, a leather hole punch, buttons, and eyelets.
- Make holes and join components. Punch holes where the pattern calls for them, then stitch or otherwise connect the pieces using the chosen fastening method.
- Assemble and decorate. Join the armor sections into a wearable arrangement, then add character features and surface decoration.
The kit maker says its plastic can be bent and cut with scissors or craft cutters, and describes it as light and strong. Those are the maker’s descriptions, not comparative test results. A category-level alternative for cosplay is EVA foam sheet; it is not one of the materials identified in the Pikachu report.
How do the approaches differ?
The available sources do not provide measured weight, durability, comparative cutting difficulty, or costs. The useful distinction is between materials and workflows documented for different purposes:
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| Approach | Material or contents reported | Pattern and assembly information | Intended result |
|---|---|---|---|
| Smith’s Pikachu costume, as reported by Adafruit in 2014 | Hard hat, plush ears, plastic garbage cans for plates, and Wonderflex for the mask | No full pattern, measurements, or assembly instructions are provided in the report | Wearable character-inspired costume armor |
| SAMURAI-J-Style kit method, page accessed October 3, 2026 | Kit page lists patterns, plastic, fabric, cords, a leather hole punch, buttons, and eyelets | Describes cutting to paper patterns, making holes, stitching, assembly, and decoration | Armor assembled using the kit maker’s pattern-based workflow |
| EVA foam as an alternative material category | EVA foam sheets; the cited armor-build report does not identify this as Smith’s material | No specific pattern or tested assembly method established by these sources | Potential costume-making material option; results depend on the chosen pattern and construction method |
What should you know before making or selling character armor?
For personal costume making, distinguish a private project from a product or service offered for sale. Sanrio’s official intellectual-property guidance says only Sanrio and authorized licensees can make or sell products or services featuring its character names or images. Its examples include homemade products and mash-ups that alter Hello Kitty’s outfit or combine Sanrio art with non-Sanrio images. Sanrio also describes personal use within a limited private circle separately and says commercial selling generally will not qualify as fair use. This is Sanrio’s guidance, not individualized legal advice.
For a business seeking permission, Sanrio’s business-opportunities page lists licensing contacts by territory, including a U.S. contact. That listing is a possible licensing route, not permission to sell fan-made goods.
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Are there official Sanrio craft products to use as inspiration?
Official licensed products can offer adjacent craft or character-building inspiration, but neither of these examples is a samurai armor kit or a source of the materials in Smith’s build.
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- Sanrio announced the FancyDeco Sanrio Characters set on September 25, 2026. It is a licensed craft set for making seven small decorative goods, sold through toy and electronics retailers and e-commerce, including Amazon.
- Kawada’s official Nanoblock catalog lists HELLO KITTY KIMONO (item NBCC_215), released in Japan on February 1, 2025, with 140 pieces and a Japan target age of 12+.
Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.
