Various cardboard kids craft project examples from Out of the Box
Box robots project spread from Out of the Box

How to Make A Box Robot Halloween Costume: Kids’ Cardboard Craft Project

How to Make A Box Robot Halloween Costume: Kids’ Cardboard Craft Project

Looking for a great Halloween costume for kids? Look no further! Out of the Box is chock-full of homemade Halloween inspiration. From bright and bold animal masks to valiant knights’ helmets, there’s no shortage of clever cardboard Halloween crafts.

Get started below with our box robots Halloween costume project. Tip: for extra spook-factor, try decorating with dark or glow-in-the-dark paint!

Watch the Build Your Own Recycled Robot video to see the project from start to finish, or follow the step-by-step instructions below. You can even download the full PDF instructions here.


How to make cardboard box robots

To make this fantastic robot costume, you’ll need a big box for the robot’s body, a square box for its head, and two smaller boxes for its hands. Make sure the boxes are big enough for you to wear. You’ll be using cardboard circles and cups to add the robot’s ears and eyes.

You will need:

paper cups
large plate
strong tape
cardboard boxes

1. Place the square box over your head and mark the positions of your eyes. Then remove the box and draw around the dots. Cut this shape out to make a slot for you to see through.

2. To create the ears, trace around a large plate on a piece of card. Mark the center of the circle with a cross, then cut the circle out.

3. Cut along one arm of the cross from the outside of the circle to the center.

Cut short slits across the other arms of the cross and fold them upwards to make tabs.

4. Pull each circle into a cone shape. Secure the overlapping edges of the cone with strong tape.  Keep the tabs at the center folded over. Repeat steps 2-4 to make a second ear.

5. To attach the ears, tape the tabs at the center of each cone to the sides of the box.

6. Now, make the eyes. Cut the base off two paper cups.

Make slits around the bottom of each cup to create tabs.

7. Fold the tabs outwards so that you can easily stick the eyes to the robot’s head.

8. Stick the eyes to the head by taping the tabs down.

9. Draw an antenna shape on cardboard (You can use the photo below as a guide if you like!) Cut the shape out.

10. Make a support for the robot antenna. Cut out a small rectangle with tabs on two of the sides as shown, and fold the tabs up.

11. Tape the support in place on top of the robot’s head, then shape the antenna to the support. Tape the longer flap to the head, and the antenna to the shorter flap.

12. Now make the robot’s body. Cut off one of the sides of the large box. Then draw a U shape on the opposite side and cut it out.

13. Use a large plate to draw circles on the other two sides of the box. Cut the circles out to make holes for your arms.

14. Next, make the robot’s hands. Cut out two rectangular pieces of cardboard, roll them into tubes, and secure them with strong tape.

15. Take one of the small boxes and draw around the tube on each shorter side near the bottom. Then cut holes where you have drawn.

16. Push a tube through the two holes to make handles you can hold when you wear them. Repeat steps 15 and 16 to make the other hand.

17. Finally, decorate each part of your robot! Paint a base coat first and let it dry. Then paint on futuristic designs. Make your decorations look like buttons, dials, screens and switches.

Why not make your robot even more high-tech by adding three-dimensional features? Try sticking on plastic lids, parts of egg boxes, and other cardboard shapes.


Out of the Box will broaden your child's imagination and develop craft skills through interactive play and creativity with clear step-by-step instructions showing how to build 25 astonishing cardboard models.

Kids can build something brilliant with recycled card, from castles to animal masks, dens and even lizards! They'll be astounded at what the humble cardboard box can be transformed into. Out of the Box is a new approach to recycling that will provide hours of entertainment and endless fun.

Image credit: Jack-o'-lantern image: Mike Flippo / flippo

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Out of the Box Out of the Box

Twenty-five interactive cardboard model projects that engage kids' creativity and "out of the box" thinking Read more

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