The process of how to make a plush toy

Do you know the production process of how to make a plush toy in factory?

I want to show you the whole production process of making plush toys in factory.

Usually to complete a plush toy, it needs follow steps.

1. Get the 2D or 3D design artwork. This is made by our designers which are familiar with different market. This is the most creative part. Good designers always have the most hot selling items, I think that is because they put their love in their art.

2. Our pattern makers will make the paper patterns according to the artwork. The paper patterns mean the fabric cutting pieces.  This process is also very difficult and important part during the whole production process. Because it is a construction process. From 2D effect to a 3D effect but use 2D factors. A good pattern maker can save the cost of the plush toy with simple patterns but not affect the shape of toy.  After stuffing, the toy will be almost the same as the artwork. Our pattern makers are all have more than 20year experience.

3. After the patterns of the toy are confirmed, we will find the correct fabrics and materials to make the products. So the 3rd step is prepare the materials.

4. Cutting the fabrics according to the paper patterns. We will use different ways to cut the fabric. Such as Lazar cutting machine.

Heating cut

Electronic clipper cutting

5.If it needs embroidery or printing, we will arrange them in the meantime.

6.Sewing the cutting fabric pieces.

Usually to control the consistent quality of the plush toy, each worker will sew separately part of the toy. Such as some workers will only assemble the legs, some only the feet, then some assemble all the part together. So it can help making the quality of the whole patch more consistently.

7. If the toy needs plastic eyes, we have to attach the eyes or noses before stuffing. And we have to melt the back of the eyes to make the eyes and noses more constantly. Because the toy must pass the safety testing. Otherwise it will have the risk of taking out by children.

8.Stuffing

After sewing part, then we will make the stuffing. Normally we will use polyester cotton to stuff the toy.  But sometimes, we also will use foam and beans to stuff the toy and some other different materials. At here, I only introduce the stuffing with PP cotton stuffing. In order to protect the environment, now most of the PP cotton are made of recycled polyester, which come from the recycled plastic bottles.

9.Hand stitching

Aer stuffing, it needs hand stitching to close the hole where stuff the PP cotton.

10.Inspection

After hand stitching, we will do inspections, we will check the shape and other parts of the plush toys, to see if the shape is ok, if there are any holes, there is a quality checking list, after checking, we will go to the next process.

11.Needle checking

This is very important for safety as well. All the toys must pass the needle checking machine to make sure there is no needle or any other metal pieces inside the toy.

12.After these, we will do packing according to client’s requirements.

This is almost the whole main process of the production. For some small process, such as attach the hangtags, I did not introduce it very clearly.  While I think you can know it form the above instruction already. If you are interested in this, please send us your feedback, I can reply you guys separately.