I have to make a cake with buzz lightyear for a friend and she wants a two tier cake and the second tier to be a buzz...how would you guys do this? would you carve the cake or make a figure and if so any ideas or tips would be appriciated?

That's going to be kind of hard. I'd try to suggest you make a figure of buzz instead of having to carve the cake for him.

I guess I would ask the friend what she means -- did she want a carved 3D cake on top of a regular round or square cake, or did she just mean she wants a figure or picture of Buzz on the top of the top tier (decorated kind of like you'd do a sheet cake), or what?

Or, if you're doing this cake as a favor or a gift, rather than as a business transaction, you might just tell your friend what you're able to do. A figure would certainly be easier.