What is the manufacturing process for plush toys?

 1、 Cropping. The traditional cutting methods mainly include hot cutting, cold cutting, and manual cutting. Nowadays, some factories have started to use laser cutting, and some places have also used net cutting machines from the clothing industry for cutting. Different fabrics can be tailored to different cutting methods. Generally speaking, manual cutting has low accuracy and poor efficiency. Cold cutting is a combination of steel grinding tools and a press to cut toy fabrics, suitable for multi-layer cutting of relatively thin fabrics with high efficiency. Hot cutting is a board mold made of gypsum board and hot melt wire, which is fused and cut into toy fabrics after being powered on. This hot cutting method is more suitable for thicker fabrics of synthetic fibers and cannot be cut in multiple layers. The new type of laser cutting has very high accuracy, relatively low labor consumption, but slightly slower speed, and the price of the machine is relatively expensive. Of course, the double headed laser cutting can make up for the speed gap. The issues to pay attention to in cutting are the direction, color difference, and quantity of material pieces of toy fabrics, and cutting must be scientifically arranged to save a lot of fabric and avoid unnecessary waste. The safety of electricity consumption is particularly important in cutting this level.

2、 Sewing. The sewing process involves sewing the cut toy pieces together to form the basic shape of the toy, which is beneficial for later filling, organizing, and ultimately completing the product. The sewing machines used in the toy industry are mostly high-speed flat sewing machines for industrial use, and household sewing machines are not very suitable for the production and processing of plush toys. Everyone in the industry knows that in the sewing process, aligning the stitching size and marking points is important. Most toys have a stitching size of 5mm, while some small toys can use a 3mm stitching element. If the stitching size is different, deformation or asymmetry may occur, such as differences in the thickness of the left and right legs; If the stitching of the marked points is not aligned, there may be issues such as limb distortion, facial shape distortion, etc. When using different toy fabrics, attention should be paid to using different machine needles and needle plates. For thinner fabrics, most use 12 # and 14 # sewing machine needles, and use small eye needle plates; Thicker fabrics often use 16 # and 18 # machine needles, and use large eye needle plates. During the sewing process, it is important to always be careful not to have jumpers, adjust the needle size for different sizes of toy pieces, and ensure that the stitching is intact. The starting position of the stitched piece should be careful to reverse the needle and avoid opening the stitched piece. In the process of sewing toys, the relatively difficult parts are usually sewn on the head of the toy and on the soles of the feet, such as car ears and rotating soles, which require high skills and physical fitness. Other aspects, such as adjusting the height of machine teeth based on the thickness of the fabric, and selecting the same color matching line according to the fabric color, are some common precautions. Of course, the quality inspection of the sewing team at any time, the reasonable arrangement of the assembly line, and the effective use of auxiliary workers are all key to improving efficiency and strict quality. Regular oiling, cleaning, and maintenance of sewing machines cannot be ignored.

3、 Post organization. In terms of the types of processes and equipment, the post sorting process is relatively complex. The post-processing includes eye punching, skin flipping, filling, seam opening, facial processing, shaping, hair blowing, thread cutting, needle inspection, packaging, etc; The equipment includes air compressors, punching machines, carding machines, cotton filling machines, needle inspection machines, hair dryers, etc. When punching eyes, attention should be paid to the model and specifications of the eyes, and the firmness and tension of the eyes and nose should be checked when punching the eyes; When filling, pay attention to the fullness, symmetry, and positioning of the filling area, and use weighing tools to weigh the weight of each product; The majority of toy seams are located on the back, and when sealing, attention should be paid to the size of the needle and the symmetry of the left and right sides. After sewing, there should be no obvious needle or thread marks, especially for some short and hot thin materials, and there should be no too large seam gaps at the seams; The charm of plush toys often focuses on the facial position, so manual and detailed handling of the face is important, such as fixing and trimming the face shape, hand embroidery of the nose, etc; A high-quality plush toy needs to have its final shape sorted out, removing any loose threads or attached hair, and ensuring proper needle inspection and packaging.