OEM process
Custom Plush Manufacturing Process: From 2D Sketch to Container, in 5 Controlled Steps
You do not need technical files or manufacturing experience. Send a sketch, a photo or a reference sample. We handle 3D modeling, material sourcing, sampling, bulk production, quality inspection and export shipping. Every step ends with your written approval, and NDA is signed before we open your files.
- 3-Day 3D Prototype
- Approval Gate at Every Step
- NDA First
- MOQ 100 pcs
- EN71 / ASTM F963 / CE
- FOB / CIF / DDP
Overview
The Full OEM Loop at a Glance
| Step | What Happens | Your Input | Typical Time |
|---|---|---|---|
| 0. Brief & NDA | Confidentiality agreement, project code created | Sketch, photos or reference | Day 0 |
| 1. Design Review & Quote | Feasibility check, itemized price | Quantity, target market | 24 hours |
| 2. 3D Modeling | Digital prototype for shape and color approval | Feedback on render | 3 days |
| 3. Material Selection | Fabric swatches, filling, hardware, packaging | Choose swatches | 2–3 days |
| 4. Sample Approval | Hand-built physical sample, revised until signed | Written approval | 7–10 days |
| 5. Bulk, QC & Delivery | Production, 4-stage inspection, export packing, shipping | Approve pre-shipment report | 25–35 days + transit |
Typical total from approved sample to FOB: 4–5 weeks. Mascots and complex builds take longer.
The loop, step by step
Five Approval Gates Between a Sketch and a Container
Nothing moves to the next stage until you say so in writing. That is the whole quality system in one sentence.
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Day 0 · Confidentiality
Step 0: We Sign First, Then Look
You send
Hand sketches, AI/PSD/PDF files, a 3D file, photos, or a physical sample. Any format works.
We do
Sign your NDA or ours. Create a project code. Restrict file access to named staff.
You get
A signed NDA and a dedicated project manager.
Why it matters: Unreleased designs are your asset. Patterns and molds stay under your project code and are never reused for other customers.
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24 hours · Feasibility & price
Step 1: 2D Design Review. We Check It Can Be Made, Before You Pay for Anything
You send
Target quantity, size, market and delivery date. If you are unsure, tell us your budget.
We do
Our engineers review the artwork for manufacturability: seam placement, embroidery detail, structural weak points, material fit. We flag issues early, such as a thin ear that will flop or a color that will not hold on plush fabric.
You get
An itemized quote covering unit price, MOQ, tooling and sample fee, packaging and Incoterms (FOB, CIF or DDP). Reply within 24 hours.
Risk we remove: surprise costs after you commit.
Read: How Plush Pricing Works -
3 days · Digital prototype
Step 2: 3D Modeling. See Your Product Before Fabric Is Cut
You send
Feedback on the first render.
We do
Convert 2D art into a 3D model. Proportions, facial layout, limb length, seam lines and color zones are visible from every angle. We revise until you are satisfied.
You get
A 3D prototype in 3 days, with multi-angle renders. For mascots, we add eye-line and head-weight analysis. For pillows and bags, we add dimension and function checks.
Risk we remove: paying for a physical sample that misses the design. Most shape and proportion changes are cheaper in 3D than in cloth.
2D art in, pattern data out -
2–3 days · Swatches
Step 3: Material Selection. Choose Fabric, Filling and Hardware With Real Swatches
You send
Your choice of swatches and finishes.
We do
Send physical swatches or photographs for fabric, fur, filling, eyes, zippers, hang tags and packaging. We recommend based on use case. For example, we recommend embroidered eyes for under-3 products and azo-free dyes for children’s items. For brand colors, we run Pantone-referenced lab dips.
You get
A confirmed material sheet that becomes the reference for the whole order. For mascots, this covers EVA density, ventilation design, lining and flame-retardant options.
Risk we remove: color mismatch and material surprises at bulk. Safety-sensitive choices are documented against EN71, ASTM F963 and CE requirements.
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7–10 days · Physical sign-off
Step 4: Sample Confirmation. Approve a Physical Sample, in Writing
You send
Written approval or a revision list.
We do
Hand-build the sample with production-grade materials and the final pattern. This is the plush toy sampling process buyers care about most. We photograph it from six angles, measure it against the drawing, and ship it to you. Revisions continue until you sign off. We then freeze the approved sample as the reference for the whole batch.
You get
A physical sample, a measurement sheet and a photo report. For mascots, we arrange a fit and vision test with a wearer or provide a video test.
What about the sample fee?
Sample fee covers patterning, materials and hand labor. It is credited against your bulk order once the order reaches 500 pcs. Details are on your quote.
Risk we remove: a bulk batch that does not match what you approved.
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25–35 days + transit · Bulk
Step 5: Bulk Production, 4-Stage QC and Export Delivery
You send
Deposit and final packaging confirmation.
We do
Cut, embroider, sew, stuff and finish in our own factory. Production schedules and photos are shared weekly. Four checkpoints protect quality:
Four quality checkpoints Stage Check IQC (Incoming) Fabric color, pile density, filling weight, dye reports IPQC (In-line) Seam strength, stuffing weight, embroidery alignment FQC (Final) Hidden-needle and metal detection, AQL 2.5 / 1.0 sampling OQC (Pre-shipment) Carton count, labeling, drop test, photo report to buyer Packing & shipping
Polybag, hang tag, barcode, FBA label or retail box. Vacuum compression lowers freight cost. FOB, CIF and DDP available, with commercial invoice, packing list, certificate of origin and test reports.
You get
A pre-shipment inspection report and photos before the goods leave. Third-party inspection is welcome and we support it.
Risk we remove: quality issues discovered at your warehouse.
FQC & metal detection 
OQC & carton labeling 
Pre-shipment staging
Mascots
How OEM Mascot Production Differs
The structure is the same, but the engineering is different.
EVA mascots
After 3D modeling we carve the head from high-density EVA, test ventilation and eye-line on a wearer, then build the costume body. Sample: 10–15 days.
EVA 3D Carving CostumesInflatable mascots
We test seam airtightness, fan noise and battery runtime during sampling. Batteries ship with UN38.3 documents.
Inflatable Advertising MascotsPackaging
Mascots ship in protective cartons or crates, with CBM and weight quoted before you confirm.
What to prepare
Don’t Have Perfect Files? That Is Fine.
Any of these is enough to start. We turn them into production-ready files.
Most of our projects begin with something a factory would reject on paper: a napkin sketch, a screenshot from a game, four phone photos of a competitor’s toy. That is a normal starting point, not a problem.
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A hand sketch or screenshot
Proportions can be estimated. We confirm them in 3D before anything is cut.
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Photos of a reference product
Front, back and side. We work out the pattern from the images and tell you what will change.
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A pet or character photo set
Four to six angles. The eyes and head shape are what make a character recognisable, so get close-ups.
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A brand guideline with Pantone codes
We run lab dips against your references so the bulk fabric matches what marketing approved.
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Target quantity, market and deadline
The three numbers that decide your price tier, your testing scope and whether sea freight is even possible. Send them even if they are rough.
FAQ
Custom Plush Manufacturing Process: Common Questions
How long does the whole process take?
3D prototype in 3 days, physical sample in 7–10 days, bulk production 25–35 days. Complex mascots take longer.
What if I do not have a 3D file?
We build it. 2D art, photos or a physical reference are enough.
How many sample revisions are included?
Revisions are included until the sample matches the approved 3D design. Major redesigns may need a new quote.
Can I visit or audit the factory?
Yes. We welcome visits and video audits, and support third-party inspection.
Who owns the molds and patterns?
You do. They are stored under your project code and are never reused.
What if bulk differs from the sample?
We inspect against the frozen sample at four stages. Deviations beyond AQL are reworked before shipment.
Design review
Start With a Free Design Review. No Technical Files Required.
Send whatever you have. You get a manufacturability note, an itemized price and a calendar back within 24 hours.
- NDA signed before review
- Three quantity tiers quoted at once
- Sample fee credited at 500 pcs