Custom Stuffed Animals & Plush Toys Manufacturer-Safety Certified

1. Minky Fabric (Super-Soft Plush)

Minky is one of the most popular fabrics for modern plush toy production, especially in the baby and gift market. It is made of 100% polyester with a short, velvety pile (1.5–3 mm) that feels silky to the touch. Its knit backing provides moderate flexibility, which makes sewing smooth curves easier, while maintaining overall durability. Standard weight ranges from 180–260 g/m², with variations like “dimple minky” (raised dot texture) that add tactile interest.

Minky is widely used for baby plush animals, cuddle toys, pillows, and premium plush lines, as its luxurious softness creates strong consumer appeal. It also works well for sublimation printing when a white base is used, allowing full-color designs. While the fabric can stretch slightly, proper seam reinforcement eliminates distortion. Minky is certified safe when dyed with OEKO-TEX compliant colors, making it suitable for markets requiring EN-71 and ASTM F963 certification. For brands targeting premium or infant plush categories, minky is often the first-choice material.

2. Velboa (Short-Pile Economy Plush)

Velboa is a short-pile, low-cost plush fabric that offers crisp definition, making it perfect for mass production of stuffed animals with fine details. It typically weighs 200–280 g/m² with a pile length of 1–2 mm, and features a woven or knit backing for stability. Compared to minky, velboa has a slightly firmer handfeel, which helps maintain shape and reduces seam stretching during sewing.

This fabric is especially popular for wholesale plush toys, promotional keychain plush, and detailed animal characters because it delivers a clean, polished appearance. Its short nap also makes it an excellent surface for embroidery and appliqué. Velboa is widely available in a broad range of solid colors and animal prints, making it versatile for brands with varied design requirements.

The advantages of velboa include affordable cost, minimal shedding, and strong dimensional stability. Its main limitation is that it does not feel as buttery soft as minky, which may affect perception in the premium segment. However, for high-volume retail orders or promotional giveaways, velboa offers an ideal balance of cost-efficiency and consistent quality.

3. Long-Pile Faux Fur (Shaggy or Realistic Fur)

For plush toys that need a luxurious, realistic, or eye-catching appearance, long-pile faux fur is the go-to fabric. It is manufactured with pile lengths ranging from 20 mm to 70 mm, supported by a knit backing that can include spandex for stretch. Fabric weights typically range from 350–800 g/m², making it heavier and more substantial than short-pile plushes.

Long-pile faux fur is commonly used in wildlife plush animals (lions, wolves, bears), premium teddy bears, decorative plush pillows, and collectible dolls. It creates lifelike texture, especially when used for manes, tails, or trim. However, this fabric requires skilled cutting and sewing, as its long fibers can shed and obscure seam lines. Manufacturers often use edge-locking or vacuum cleaning processes during production to minimize fiber loss, which is essential for passing EN-71/ASTM shedding tests.

While it has higher material cost and yield loss compared to short-pile plush, faux fur significantly enhances perceived product value. It is particularly attractive for limited-edition or premium plush ranges, where appearance and tactile appeal justify higher retail pricing.

4. Sherpa / Borg Fleece

Sherpa (sometimes called Borg fleece) is a curly, loop-pile fabric designed to mimic natural sheepskin. With a pile height of 3–6 mm and fabric weights of 250–380 g/m², it delivers a cozy, fluffy appearance and soft handfeel. The backing is knit, providing enough stretch for sewing curves while retaining stability for stuffing.

This fabric is ideal for classic teddy bears, winter or Christmas plush collections, baby comfort toys, and lifestyle plush pillows. Sherpa’s texture helps hide seam lines, making it suitable for rounded shapes. The loops create a warm, cuddly impression that resonates with buyers seeking comfort products.

However, sherpa is bulkier than short-pile plush, which can increase shipping volume. Its loop construction may also snag if not carefully finished. To improve product performance, manufacturers choose sherpa variants with denser loops that resist pulling. As with other fabrics for infant toys, sherpa should be tested for low lint shedding and saliva/sweat fastness, ensuring safety for sensitive users.

For brands launching seasonal or cozy-themed plush lines, sherpa adds strong emotional and tactile value.

5. Polar Fleece / Microfleece

Polar fleece and microfleece are napped polyester fabrics that offer an economical alternative to pile plush. They typically weigh between 180–300 g/m² and feature a brushed surface on one or both sides, creating a soft but matte finish. Unlike velboa or minky, they do not have a pile direction, which simplifies cutting and reduces fabric waste.

Fleece is widely used in value-focused plush animals, pet plush toys, and plush accessories like blankets or apparel add-ons. It is easy to sew, lightweight, and available in an enormous color range. For brands targeting budget-conscious markets or promotional campaigns, fleece provides excellent cost efficiency while still delivering softness.

The downside of fleece is its lower luxury perception and susceptibility to pilling. To counter this, many factories specify anti-pill grades, which improve durability and meet higher abrasion standards. With the right finishing, fleece plush toys can achieve compliance with EN-71 and ASTM F963 requirements for colorfastness, flammability, and mechanical safety.

Fleece is a practical choice for high-volume production where affordability and consistent supply matter most.

6. Velvet / Velour (Knitted Pile)

Velvet and velour are short, dense pile fabrics known for their luxurious sheen and premium handfeel. Typically made from polyester or poly-blends, these fabrics weigh around 220–320 g/m² with a pile height of 1–2 mm. Unlike velboa, velvet has a smoother surface and subtle shine, making it perfect for high-end plush toys and collectible dolls.

Velvet is often used in premium teddy bears, fashion-inspired plush dolls, holiday gift ranges, and boutique collections. Its elegant finish makes it suitable for brands targeting adult collectors or premium gift markets. The fabric also takes embroidery well, allowing detailed features like eyes, noses, or logos.

However, velvet is more delicate compared to short-pile plush. It can show pressure marks or shading if compressed during storage, and requires careful packaging to maintain its appearance. While it is slightly more expensive, velvet delivers a strong perceived value upgrade that helps brands justify higher retail prices. Compliance-wise, it generally performs well in EN-71/ASTM testing, though rub fastness should be confirmed for deep or dark shades.

7. Faux Suede / Microsuede

Faux suede, also called microsuede, is a brushed fabric with a matte, sueded finish that mimics real leather while remaining soft and lightweight. Weights typically range from 160–260 g/m², with minimal stretch depending on backing. Its smooth, durable surface is highly resistant to abrasion, making it a versatile material in plush toy manufacturing.

Microsuede is primarily used for paw pads, muzzles, noses, ears, and clothing accents on plush toys, adding textural contrast and realism. Some brands also use it for minimalist plush dolls or decorative cushions, where a more sophisticated, non-furry look is desired.

Advantages include durability, stitch definition, and upscale perception. Microsuede holds seams firmly, resists pilling, and works well for precision embroidery or appliqué. On the downside, it can show finger-marking on lighter shades, so proper finishing and QC are essential.

Compliance-wise, faux suede fabrics are stable and non-shedding, making them a safe option for toys that require mechanical seam strength and abrasion resistance tests. This makes them especially suitable for markets where durability and longevity are key selling points.

8. Corduroy (8–21 Wale)

Corduroy is a ribbed woven fabric with parallel ridges (“wales”) that create a tactile and vintage look. It is often made from cotton or polyester blends, with weights between 200–320 g/m². The wale count (number of ribs per inch) can vary, with finer wale counts giving a softer, dressier appearance and wide-wale versions providing a rugged, bold texture.

In plush toy manufacturing, corduroy is used for retro teddy bears, lifestyle plush toys, clothing on plush dolls, and durable limbs. Its ribbed structure adds character, making toys stand out in the market. It is also a favorite in Scandinavian and European toy designs where a handmade aesthetic is valued.

Advantages include high abrasion resistance, strong durability, and unique tactile identity. Corduroy plush toys can easily differentiate a brand in a crowded marketplace. The limitations include wale alignment challenges (patterns must be cut consistently to maintain symmetry) and slightly higher stiffness compared to velboa or fleece.

For compliance, corduroy performs well under EN-71 mechanical and chemical standards, but yarn-dyed or reactive-dyed variants should be prioritized for better colorfastness.

9. Cotton Twill / Canvas

Cotton twill and canvas are firm, structured woven fabrics traditionally used for workwear and bags, but increasingly adapted into plush toy manufacturing for a handmade, rustic, or minimalist look. They usually weigh 180–300 g/m² and have a tightly woven structure, making them durable and resistant to tearing.

These fabrics are often used in minimalist plush dolls, vintage teddy bears, hybrid décor plush (cushions/toys), and pet plush toys. Because of their firm structure, they are especially suitable for plush toys where shape retention and durability are more important than softness.

The main benefits are strength, eco-friendly perception (especially organic cotton canvas), and ease of embroidery or printing. They also offer good breathability compared to polyester plush fabrics. The drawback is that they are less cuddly than pile fabrics, so they are less suitable for baby plush unless blended with softer materials.

For compliance, cotton twill and canvas should be finished with formaldehyde-free and azo-free dyes to meet EN-71 and REACH standards. For eco-conscious brands, GOTS-certified organic cotton canvas is increasingly in demand.

10. Organic Cotton (Interlock, Jersey, Double Gauze)

Organic cotton fabrics are made from GOTS- or OCS-certified fibers, ensuring they are grown without harmful chemicals and processed under strict environmental standards. Common constructions include interlock knits (smooth, stable), jersey knits (light stretch), and double gauze (soft, breathable, textured), typically weighing 140–220 g/m².

Organic cotton is the material of choice for baby plush toys, comfort blankets, teething-age plush accessories, and eco-branded plush ranges. Its natural softness and breathable texture make it ideal for products targeted at newborns and sensitive markets.

The advantages are eco-friendly credentials, baby-safe perception, and strong marketing appeal in regions like Europe and North America. Limitations include higher cost compared to polyester plush, lower color vibrancy, and shrinkage risks if not pre-treated.

Compliance-wise, organic cotton plush toys should be tested for saliva/sweat colorfastness, small-part risks, and EN-71 Part 3 chemical safety. With growing consumer demand for sustainable toys, organic cotton is a premium but strategically valuable choice.

11. Terry / Terrycloth

Terrycloth is a loop-pile fabric commonly associated with towels, but it is also used in plush toy manufacturing for its playful, sensory texture. Typical weights range from 220–350 g/m², with loop lengths between 1–3 mm. It can be woven or knitted, with knit terry being more flexible for toy production.

Terry is commonly applied in baby plush toys, sea animal characters, bath-time themed plush, and sensory comfort toys. Its loops provide a tactile experience that encourages touch and engagement, making it especially suitable for infants.

Benefits include absorbency, sensory appeal, and durability. However, loops may snag if not tightly constructed, so manufacturers prefer dense-loop terry fabrics for safety. To enhance softness, terry is often pre-washed or blended with organic cotton.

For compliance, terry plush must undergo loop pull tests, lint shedding checks, and saliva fastness testing for infant markets. Proper quality control ensures that it remains safe, functional, and visually appealing.

12. Denim / Chambray

Denim and chambray are woven cotton fabrics known for their durability and casual aesthetic. Denim is heavier (200–300 g/m²), often indigo-dyed, while chambray is lighter (150–220 g/m²) with a smoother hand. Both fabrics are highly resistant to wear and tear, making them popular for pet plush toys, lifestyle plush dolls, and toy clothing accents.

Denim plush toys have a rugged, fashion-forward appeal, often associated with “urban” or “handcrafted” toy lines. Chambray, with its lighter structure, is often used for clothing on plush dolls or as a minimalist body fabric.

The advantages are strong abrasion resistance, trendy aesthetic, and long lifespan. Drawbacks include added weight, limited softness, and seam bulk compared to knit plush fabrics. For toys targeting lifestyle or pet categories, denim provides differentiation and functional value.

Compliance requirements include wash-down finishing to reduce dye rub-off, nickel-free trims, and azo-free dyes for child safety.

13. Spandex-Blend Stretch Plush (Stretch Velboa/Minky)

Stretch plush fabrics are modified versions of velboa or minky that incorporate 5–12% spandex, providing 2- or 4-way stretch. Weights range from 200–300 g/m², with pile lengths around 1–2 mm. The elasticity makes it easier to cover complex shapes with fewer seams.

This fabric is especially useful for mascot plush toys, detailed character plush, and plush dolls with unique contours. Its stretchability reduces the number of panels needed for shaping, resulting in smoother surfaces and fewer visible seams.

Advantages include versatility in shaping, smoother appearance, and durability under stress. The challenges are potential seam creep or distortion if not sewn with proper techniques (e.g., zig-zag stitches and seam tape).

Compliance-wise, stretch plush must be tested for seam strength and elongation resistance. When properly engineered, it passes EN-71 seam pull requirements while delivering a high-quality finish for complex designs.

14. Eco / Recycled Polyester Plush (GRS Certified)

Recycled polyester plush is an eco-friendly alternative to conventional plush fabrics, made from post-consumer recycled PET bottles. It looks and feels identical to standard velboa or minky, with weights ranging from 180–280 g/m², but offers GRS (Global Recycled Standard) certification for supply chain traceability.

This fabric is increasingly demanded by global retailers, eco-conscious brands, and corporate buyers with ESG commitments. Applications include sustainable teddy bears, eco-plush ranges, and promotional toys. By using recycled materials, brands can highlight sustainability while still delivering softness and durability.

The advantages are eco-marketing appeal, regulatory compliance, and alignment with retailer sustainability goals. The limitations include a slightly higher cost and the need to maintain strict documentation for GRS audits.

Compliance requires chain-of-custody certification, transaction certificates, and GRS labeling approval. For brands selling into Europe or North America, recycled plush is a strong differentiator and marketing advantage.

15. Felt (Polyester or Wool Blend)

Felt is a non-woven fabric created by compressing and matting fibers together. It is typically available in 1–3 mm thickness sheets or rolls, with no fraying edges. Felt has a dense, smooth texture and comes in a wide range of colors.

In plush toy manufacturing, felt is rarely used as the main shell material but is invaluable for details such as eyes, noses, appliqués, badges, and accessories. It can be laser-cut or die-cut for precision, making it ideal for logos and small decorative pieces.

The advantages of felt include clean-cut edges, ease of shaping, and cost-effectiveness. Its drawbacks are pilling over time and limited flexibility compared to knit plush fabrics.

Compliance-wise, polyester felt generally performs well in EN-71/ASTM testing, but wool blends may require additional checks for lint shedding. For small parts, ensure felt pieces are securely stitched or embroidered to pass mechanical pull tests.

Quick Fabric Comparison

Fabric Selection by Product Type

Printing & Color Notes

• Sublimation/photo plush: White minky/velboa for vivid prints.
• Rotary/transfer prints: Use for animal skin patterns, logos, or panels.
• Colorfastness: Target ≥4 (wash, dry, saliva/sweat). Avoid pigment systems that crock.

Sewing & Engineering Tips

• Needles/Thread: Ballpoint needles for knits; poly core thread Tex 27–40 for strength.
• Seam Tech: Overlock + lockstitch; consider seam tape on stretch plush; ≥0.8–1.0 cm seam allowance on long-pile.
• Shedding Control: Vacuum and edge-seal faux fur; brush nap post-sew.
• Embroidery: Backing stabilizer for minky/velour to prevent tunneling.

Compliance & Testing Checklist

• Toy Safety: Plan for EN-71/ASTM F963 relevant parts; confirm material safety (azo-free, heavy metals, phthalates if applicable), flammability requirements, and small-parts rules (use embroidered/stitched eyes for infants).
• Mechanical: Seam strength, tensile on attachments, stuffing loss.
• Chemical: pH, perspiration/saliva colorfastness, formaldehyde (for cottons), disperse dye restrictions for polyester.
• Labeling: Fiber content, care, country of origin, batch/traceability; keep test reports aligned to final colors/lots.