Creator and executive producer Deborah M. Manchester says that the idea for the series began in January 1995, when she had foot surgery in Columbus, Ohio and her foot was hanging from a cast that she had to wear for almost six months. Manchester designed a woven cast cover and decorated it with alien creatures. She offered the covers to area hospitals, where the nurses and their young patients loved them. The cast covers turned into plush toys, which attracted producers interested in making a TV show.
The Zula Patrol TV Episode Guide :