Well, for starters these were 90's character designs and It wouldn't be until the mid to late 2000's when we'd finally see a push to make characters appear more screen accurate. Also, I believe that Buzz and Woody were rushed into production after Toy Story became a bigger success than Disney originally anticipated. To get them into the parks as quick as possible, they didn't spend the usual amount of time fine-tuning the designs and doing a test-and-adjust. This decision resulted in long-lasting issues with fit and function that resulted in high levels of discomfort and frequent performer injuries. I really can't stress how long overdue this re-design was.You have to question how they ended looking so bad on the old faces
On a side note, RIP Bullseye. You may have destroyed people's bodies, but you always looked so darn cute doing it.