Legal Question in Intellectual Property in California

Without permission from the trademark holders, no.

Well, I may have answered too quickly. If he was making them in his own backyard for himself, it is doubtful anybody would find out. If he was using an organization like cafepress, etc., I don't think they would print them.

For himself only, nobody is going to sue him. If he sells or gives them away to anyone else, different answer.