What are the production processes and types of fillings for plush toys?

The texture of plush toys is a crucial factor. Many plush toys have poor tactile qualities, with fur that is not soft enough and fabrics that lack comfort. Such products naturally fail to attract attention in the market. Additionally, shedding is a significant issue. If the fur is not fixed well or of poor quality, shedding becomes more likely. These are problems that plush toy manufacturers must avoid. Below is an introduction to the production process and the types of fillings used in plush toys. Feel free to read on!

1. First, contact the plush toy manufacturer via phone or email and provide photos to confirm if production is feasible. If possible, the manufacturer will quote based on the customer's material requirements.

2. Designers at the toy factory create sample patterns based on design drafts, calculate the required materials for each product, and produce a prototype.

3. Once the prototype is approved by the client, mass production is initiated.

4. The plush toy manufacturer uses the sample provided by the design department to create molds and cut materials in the molding and cutting workshop.

5. Upon receiving materials, they are inspected and cut (either manually or with a press).

6. Sewing workers use machines to stitch the main body, attach fabric labels, sew accessories, and conduct random inspections during production to ensure the empty shell matches the approved sample after being filled with PP cotton.

7. Components like noses, eyes, and joints are installed. For some plush toys, embroidery work is completed before sewing.

8. Fill the toy with the designated filling material. Specific weights of PP cotton are inserted into the toy using compressed air.

9. The cotton filling opening is hand-sewn, the toy is shaped, and a high-pressure air pump is used to blow away any loose fibers.

10. Tags are attached, and any exposed threads are trimmed. The fur length is adjusted, especially around the toy's eyes, nose, and mouth.

11. The product undergoes inspection and metal detection.

12. Packaging is carried out according to the customer’s predetermined requirements.

1. PP Cotton  

Also known as doll cotton or stuffing cotton, this material is made of recycled polyester short fibers. It is a common synthetic fiber available in standard and hollow types. PP cotton is highly elastic, fluffy, smooth to the touch, cost-effective, and has good warmth retention. It is the most commonly used filling for plush dolls, making it a staple in many plush toy factories.

2. Washed Cotton  

Washed cotton is made from cotton fabric that undergoes special treatment, giving it a softer texture, a more subdued tone, and a slightly vintage look with mild creases. This material resists deformation, fading, and requires no ironing. High-quality washed cotton often has a uniform layer of fluff on its surface, offering a unique style.

3. Down Cotton  

Down cotton is produced from ultra-fine fibers of various specifications through special processes. Its texture resembles down, hence its name. It is also referred to as silk cotton or hollow cotton. This filling is lightweight, soft, evenly textured, and provides excellent insulation. It does not deform easily, does not leak fibers, and contains no hard or foreign objects.

4. Plastic Pellets  

Small plastic pellets are used in plush toys primarily to maintain a standing or sitting posture. These pellets are denser than cotton fillings and are typically placed in the base or feet of the toy to lower its center of gravity, ensuring stability when placed on flat surfaces.

5. Foam Beads  

Foam beads, also known as snow beans, are high-polymer materials with excellent cushioning and shock-absorbing properties. They are lightweight, elastic, and absorb and disperse external impact through bending, providing a buffering effect. Unlike traditional foam, foam beads are durable, resistant to deformation, and retain their shape well. They are especially comfortable when used in plush pillows or cushions.

Thank you for reading. The above content is provided by Demeng Toys, summarizing the production processes and types of fillings for plush toys. Some information is sourced from the internet and is for reference only. If you wish to learn more about custom toy production, feel free to contact us. We are at your service!