I found some cheap ones ($8) in comparison to the Disney Store on ebay.com. You should shop around a little on websites such as eBay and Amazon to find some great deals!
We had a pair of ears made yesterday at Downtown Disney. It wasn't cheap -- $24 including the name ($14 for the ears.) However, my DS8 really liked having his ears made and watching his name sewn on the ears. I never had the ears made for him when he was 3 years old (the last time he was at WDW) so this was a lot of fun for me too.
The Disney website has a lot reviews that say that the stitching is crooked - with buying in person, you have a chance to look at the finished product and make sure you like the quality.
You can also see the different fonts and various colors that are available.
I got ears on ebay. We were having a disney pirate party prior to our bday trip and found them. I was able to give the ears as a gift prior to the trip at the party.
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