This page is a reference, not a sales page. It states the standards, the specification fields, the order quantities and the lead times that a custom plush programme is built on, so that a buyer can compare suppliers against the same numbers.
Last reviewed 27 October 2026.
What standards apply to a custom plush toy?
The applicable standard depends on the market where the toy is sold, not on where it is made. A toy made in China for the United States is tested to the United States rules.
| Market | Standard or rule | What it covers |
|---|---|---|
| China | GB 6675.1 to GB 6675.4 | Basic safety requirements; mechanical and physical properties; flammability; migration of certain elements |
| European Union | EN 71-1 | Mechanical and physical properties |
| European Union | EN 71-2 | Flammability |
| European Union | EN 71-3 | Migration of certain elements |
| United States | ASTM F963-23 | Toy safety. Mandatory: 16 CFR § 1250.2(a) requires each toy to comply with all applicable provisions of ASTM F963-23 |
| United States | 16 CFR part 1501 | Small parts, for articles intended for children under 36 months |
| United States | 16 CFR part 1303 | Lead in paint and surface coatings, banned at 0.009% by weight |
| United States | 16 CFR part 1307 | Eight specified phthalates, prohibited above 0.1% each |
| United States | 16 CFR part 1110 | The Children’s Product Certificate and its filing with CBP |
Choosing the standard set: it follows the market of sale
Where will the toy be sold?
|
+-- China -----------> GB 6675.1 -.4
|
+-- EU / UK ---------> EN 71-1, EN 71-2, EN 71-3
| plus CE marking and a technical file
|
+-- United States ---> ASTM F963-23 (via 16 CFR 1250.2(a))
| + 16 CFR 1501 if under 36 months
| + 16 CFR 1303 and 1307 chemical
| + 16 CFR 1110 certificate and CBP filing
|
+-- More than one ---> test to each set separately.
A report written against EN 71 does not
satisfy ASTM F963, and the limits do not
convert: EN 71-3 measures migration,
the US rules measure total content.
Two consequences that decide a programme early:
- The age grade changes the test set. Under 36 months engages the small parts rule in 16 CFR part 1501 and the tighter abuse tests in 16 CFR § 1500.51; over 36 months does not.
- The decoration changes the chemical scope. A printed, coated or transferred panel is not covered by the dyed-textile determination in 16 CFR § 1500.91(d)(7), which is written as “textiles … that consist entirely of dyes”.
What belongs in a custom plush specification?
Seven numbers make a brief quotable. Without them a supplier can only guess, and a guess is where the 20% to 70% spread between quotes comes from.
| Field | Unit | Bands commonly specified for a 25 cm character |
|---|---|---|
| Shell fabric composition | % | 100% polyester, as crystal super soft, velboa or minky |
| Fabric weight | g/m² | 220 to 300 |
| Pile height | mm | 2 to 3 for velboa, 4 to 6 for minky, 8 to 12 for curly pile |
| Fill weight | g | 85 to 165 of siliconised hollow conjugate polyester fibre |
| Finished size | cm | 10, 15, 20, 25 or 30, measured as seated height |
| Embroidery stitch count | stitches | 2,800 to 5,500 |
| Age grade | months | Under 36 months, or 36 months and over |
Two of those fields are worth more than the rest.
Fill weight in grams is the only defence against a delivery that photographs correctly and sags in the shop. “Filled firmly” is not a specification.
Age grade sets the components. A washer-backed safety eye and a push-fit eye look identical through the fabric; only one holds through the 10 lb tension test required for seams and projections under 18 months by 16 CFR § 1500.51, or the 15 lb required over 18 months by § 1500.52.
From a specification to a quotation
cut panel area (m2) fabric weight (g/m2) fill weight (g)
| | |
v v v
/ nesting efficiency --> fabric weight (kg) --> fill cost
| |
v v
fabric consumed (m2) --------> fabric cost
embroidery stitch count (n) --> stitches / 1000 x rate --> embroidery cost
SAM / line efficiency --> actual minutes --> x minute rate --> labour cost
+ trims + packaging + overhead = ex-works subtotal
+ margin = FOB price per unit
What is the minimum order quantity?
100 pieces per design.
The constraint behind that number is not the sewing line, it is the setup: a pattern, a digitised embroidery file, a fabric order in the right colour way, and a sample round. Those costs are fixed, so they are absorbed across the run. At 100 pieces they are a significant share of the unit price; at 10,000 they are rounding.
Two practical notes for small buyers:
- The minimum applies per design, not per order. Three designs at 100 pieces each is a 300-piece order with three setups.
- Colour way counts as a design where the fabric has to be dyed to order. A stocked fabric colour can be swapped without a new minimum; a custom dye lot usually cannot.
How long does sampling take, and what does it cost?
5 to 7 days for a sample, including one revision round.
The fee covers pattern engineering, embroidery digitising, cutting and sewing a one-off, and the revision. It is not refundable, and it is not a deposit against the order. That is worth stating plainly because it is a question that comes up in every first conversation, and because a supplier who quotes a “refundable sample” is usually building the cost into the unit price instead.
Production after approval is 30 to 45 days for a 10,000 to 50,000 piece run, at a monthly output of 100,000 pieces.
How is the unit price built?
Not from a price list. Five inputs:
| Input | Why it moves the price |
|---|---|
| Cut area divided by nesting efficiency | The waste factor. Two cutters on the same pattern can differ by ten points |
| Fabric weight in g/m² | The largest material line, and it is a range, not a number |
| Fill weight in grams | Small per unit, but it is a material cost on every piece |
| Embroidery stitch count | Set by the digitising file, not by the drawing |
| SAM divided by line efficiency | The largest single line in the model, and the least audited |
On a 25 cm character the same drawing spans roughly $2.46 to $4.34 FOB depending only on those five inputs. The worked model, with every rate stated, is in the unit-cost guide.
Product formats and what they change
Custom plush keychain
A keychain is a smaller character with a hardware attachment, and three specification fields matter more than the rest:
- Attachment fixing. The split ring or clip is a separate component, and it becomes part of the small parts assessment if the product is sold for under-threes.
- Fill weight. Keychains are commonly under-filled relative to a standing character, because weight matters on a bag.
- Size. Under 10 cm, the embroidery detail becomes the limiting factor before the shape does.
Blind box plush
“Plush in box” is a plush supplied inside a retail box, usually as an assortment with an unknown contents mechanic. Four specification lines sit outside the toy itself:
| Line | What to state |
|---|---|
| Box dimensions and board grade | Outer size, board thickness and print method |
| Assortment ratio | How many of each colour way per carton, and the inner-pack count |
| Minimum order | Per SKU and per assortment are different numbers - agree which |
| Filling method | Which character goes in which box, verified against the assortment card |
The last line is the one that generates claims: an assortment that is packed by hand can drift from the agreed ratio across a run, and the buyer discovers it at the point of sale.
Plant plush
A plush plant - a potted form, a bulb or a leaf construction - differs from a character in three places: the pot is a structural element and usually needs a firmer fill or a weighted base, the stem frequently carries wire, and the leaves are cut from a different fabric weight than the body. Wire in a stem engages the flexure requirement in 16 CFR § 1500.51(e) and § 1500.52(e) where the component bends through a 60-degree arc under the stated force.
Lop-eared rabbit plush
The lop-ear form is a specification problem rather than a design problem: the ear is long, unsupported and hangs. That means a different fill density in the ear from the body, an interlining to stop the ear folding on itself in the carton, and a seam specification that survives being picked up by the ear. Ear length and drop are the two fields to state; without them two factories will produce visibly different toys from the same drawing.
Frequently asked questions
Which GB 6675 standards must a custom mascot plush toy meet?
GB 6675.1 covers basic safety requirements, GB 6675.2 mechanical and physical properties, GB 6675.3 flammability, and GB 6675.4 migration of certain elements. A mascot plush intended for children under 36 months must also pass the small parts assessment. A test report should name the standard part and the clause, not just state that the product complies.
What does a small-batch custom plush order cost to sample?
The sample fee covers pattern engineering, embroidery digitising, cutting and one revision round, and it is not refundable. It does not scale with the order size, which is why it is proportionally large at 100 pieces and negligible at 10,000. Ask for the fee itemised; a supplier who cannot itemise it is usually quoting a placeholder.
What is the minimum order quantity and lead time?
Minimum order is 100 pieces per design. Sampling takes 5 to 7 days including one revision, and production runs 30 to 45 days for 10,000 to 50,000 pieces, against a monthly output of 100,000 pieces. Seasonal programmes need the ocean window added on top: a retail floor set in mid-September means a brief in April.
Can one factory supply the plush and the retail box?
Yes, and for blind box formats it is preferable, because the toy dimensions, the box cavity and the assortment ratio are one engineering problem. Confirm which party is the manufacturer of record for the packaging, and which standard the combined article is tested against.
How do I compare two quotes for the same drawing?
Ask for the five inputs behind each price: measured GSM, nesting efficiency, fill grams per unit, stitch count, and SAM with the assumed line efficiency. Two quotes built on different inputs are not comparable, and the difference between them is almost never the margin.
What this page does not cover
- The rates are illustrative where they appear. Freight, labour and fabric prices move; substitute your own and the arithmetic still holds.
- Market-by-market chemical rules differ. The EU route uses REACH and EN 71-3 migration limits, which measure migration rather than total content; a US report does not satisfy it and the numbers do not convert.
- This is a reference, not legal advice. Confirm the requirements for your destination and the wording in force on your ship date with a testing laboratory.
References
-
GB 6675.1 to GB 6675.4 - Chinese national toy safety standard, parts 1 to 4 (basic safety requirements; mechanical and physical properties; flammability; migration of certain elements).
-
EN 71-1, EN 71-2, EN 71-3 - Safety of toys, European Committee for Standardization: mechanical and physical properties; flammability; migration of certain elements.
-
16 CFR part 1250, § 1250.2(a) - each toy must comply with all applicable provisions of ASTM F963-23. https://www.ecfr.gov/current/title-16/part-1250
-
16 CFR § 1500.51 and § 1500.52 - use and abuse test methods for children of 18 months or less, and over 18 but not over 36 months, including the 10 lb and 15 lb seam tension requirements. https://www.ecfr.gov/current/title-16/section-1500.51
-
16 CFR part 1501 - small parts method for articles intended for children under 3 years of age. https://www.ecfr.gov/current/title-16/part-1501
-
16 CFR part 1303 and part 1307 - lead in paint and surface coatings; specified phthalates. https://www.ecfr.gov/current/title-16/part-1303
-
16 CFR part 1110 - certificates of compliance, including the Children’s Product Certificate and its electronic filing with US Customs. https://www.ecfr.gov/current/title-16/part-1110
Related reading
- What a plush toy’s FOB price is made of: a unit-cost model you can audit
- Why the same plush toy gets quoted 21% to 76% apart
- Custom plush sampling: what actually happens in the 5 to 7 days
- Latte bear plush: a 25 cm classic teddy, the standard size band this reference assumes
- The stock catalogue: every design with its fabric, filling, MOQ and test standards
Flechazo operates a 12,000+ m² workshop with 200+ production staff and a monthly output of 100,000 pieces, running 100% needle detection and AQL 2.5 inspection. MOQ from 100 pieces per design; samples in 5 to 7 days.