Hi Sara,
A
Character Meal sounds like the perfect way to celebrate your husbands birthday.
As Character Meals are extremely popular and dining reservations can be made up to 180 days in advance, I would highly recommend that you search for availability straight away for the dates of your visit to see if there are any times available to book. You can do this on the Walt Disney World website or by calling 0800 16 90 748 from here in the UK.
Once you have managed to secure a dining reservation, you have two options available to you in terms of a birthday cake.
A 6 inch generic cake is available without prior notice by just asking your server at Table-Service restaurants. If you would like a personalised cake, one can be ordered beforehand by calling 001 (407) 827-2253.
The unofficial website www.disneyfoodblog.com has lots of great information available about cakes as well as pictures which might be useful to look at - to access these, just search for Disney World Cakes FAQ once you are on the website.
Wishing you a magical holiday filled with memories which will last a lifetime!
Emma