If we discuss about plush toys, what often comes to your mind? Based on our vast observations as a plush toys factory or manufacturer in China, we find that all are thinking about soft, cuddly figures like teddy bears, bunnies, mermaid or character dolls. However, these toys are not just for children—many teens and adults also find comfort in collecting or hugging them. If you check the Labubu phenomenon, we think you will agree with our conclusion. That no matter your age, plush toys have a unique way of bringing joy and even acting as a stress-relief companion in daily life. Then you might wonder, how to make a custom plush toys? and how is the production? Hence, we will share our experience and knowledge in this article.
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The Plush Toy Manufacturing Process
The process of making good, cute and fun toys turns out to be not as simple as assembling a lot of material, it has a more complicated process in the factory. In this article, we will talk about the process of making cute plush toys and what is happening in the plush toy factory.
Material Selection Process
Material selection is one key process that should be done properly and carefully. Good fabric and plush toy materials are used to make good quality plush toys for customer satisfaction. Usually, the factory buys the materials from third party manufacturers that produce materials that are needed in the toy’s production.
Then, the toy factory stores the materials in the warehouse and keeps it from dust and excessive humidity to maintain materials quality. Before toy production begins, the person who is responsible for material selection will choose proper materials that are needed.
For example, a particular client wants to make one thousand blue rabbit plush toys with eco-friendly stuffed material, so the factory will choose blue fabric and stuffed material that is needed.
Laser Cutting Process
The next process after material selection is the laser cutting process. This process uses computerized laser cutting machines that are operated by experienced operators. Laser cutting process consists of a few steps until it produces raw materials that are used in the next process.
First, the operator will look for a toy design in the computer then move it into a specific application that is connected to a laser cutting machine. After it approves, then the fabric or material placed in the machine and laser cutter start to cut the material in precise measurement as in computer command.
Laser cut produces very clean cutting in the material and avoids measurement errors that sometimes happen in the manual cutting process. Plush toy factories which are already using this machine will produce clean cut plush toys in good quality.
Sewing Process
After all materials are cut by a laser machine, it is ready to send it to the sewing process. This process uses sewing machines that are operated by experienced toy tailors. The material which is still separated will assemble into one full shape that is wanted by the sewing machine.
In this department, they have each division for each shape, for example they have rabbit plush toys sew division, elephant plush toys division and many kind shape divisions. The toy’s tailors sew the shape carefully with precise measurement, so the result will be the same as prior design. Good quality shapes will produce neat and clean plush toys.
Material Turn Over and Filling Process
The next process in the toy factory after the sew process is material turn over. The workers will turn over the material manually and smooth the thread connection between the fabrics. This process should be done carefully to make sure the toys have smooth and neat shape before the toys are filled with filling material.
Besides that, smoothing thread connections will keep the thread intact and avoid looseness. After the material turn over process is done, the next process is the filling process with stuffed material such as cotton or polyester. First, the workers will do the nose or a little hole part filling, then fill the body parts.
Final Shaping and Needle Inspection Process
Final shaping is the process when the final shape of plush toys gets into manual stitching in a certain part and the workers will ensure that the toys have proper and good shape just like its design.
The final shaping process also ensures that all the toys have the same size, the same amount of filling and same shape. The needle inspection process is held to check if there are needles, or other sharp objects that are left behind by accident inside the toys. This process is mandatory to guarantee the safety of toys usage by consumers.
Needle Detector Machine
Packaging and Distribution Process
The final process at the toy factory is the packaging process. When the plush toys pass all the process and pass the quality control, the toys will get into the packaging process. The workers will wrap the toys using a clear plastic package, then double wrap them with a hot seal plastic bag to guarantee its quality. After that, the toys will be put in the box and distributed to the customer.
Conclusion
That’s all the process that happens in the plush toy manufacturer and all processes are held under the restricted safety rules. BuyChinaToys is the trusted plush toy manufacturer in China which operates a standardized and safe toy industry that produces good quality plush toys products.