Full-Cycle Plush Manufacturing Services

# From Concept to Global Distribution With Engineering-Level Control

Delsney provides a complete production pipeline for custom plush—from idea development to certified mass manufacturing.

Over 18+ years, our factories have delivered plush products for global brands, licensing companies, influencers, collectible series, and premium retailers.

Our full-cycle system integrates:

Concept refinement
Engineering design
Fabric selection
Mold creation (if needed)
Embroidery programming
Sample development
Mass production with 20+ QC steps
Export-ready packaging
Global compliance support

OEM & ODM Development Service

Engineering-Based Development for Stable, Repeatable Plush Manufacturing

OEM and ODM development at Delsney is driven by structural engineering rather than trial-and-error.

Our technical department includes:

12+ product engineers
10+ professional pattern makers
4 embroidery technicians
Material specialists for pile fabrics

Together, these teams ensure that each plush project is accurate, efficient, and compliant with international safety standards.

1. Accurate Shape Translation

Engineers analyze body ratios, limb thickness, and volume distribution to maintain character identity while ensuring manufacturability.

2. Structural Optimization

Based on data from 9,000+ historical plush samples, our team reinforces weak points using mesh layers, cross-stitching, and advanced stabilization methods.

3. Embroidery & Detail Engineering

Logo work, facial features, and decorative elements are calibrated for stitch density, edging safety, and clarity.

4. Version Control & File Management

Every project receives digital records:

Pattern versions
Embroidery versions
Revision history
QC guidelines

This ensures repeatable quality across reorders.

Supported OEM Scenarios

Merch plush for global events
Brand mascots
Licensed IP characters
Retail plush collections
Influencer merchandise
Plush-based accessories (bags, pillows, keychains)

Plush Design & Character Development

From Sketch to Plush-Ready 3-View Drawings and Production Blueprints

Delsney helps creators and brand teams convert visual ideas into manufacturable plush characters.

Our design workflow ensures accuracy in shape, personality expression, stitching path, and overall proportions.

01

Character Interpretation

Designers capture expression, posture, and signature traits while aligning them with plush-friendly shapes and materials.

02

3-View Drawing Creation

Every project receives a detailed 3-view drawing (front, side, back) showing:

Height ratio
Key curves
Stitch lines
Embroidery areas
Filling chambers
Material zones

This drawing becomes the blueprint for engineering and sampling.

03

Material & Color Mapping

The design team selects fabrics based on:

Fiber length
Surface sheen
Color brightness
Durability
Stitch compatibility

Delsney maintains a curated library of 500+ plush fabrics for matching artistic references.

04

Expression Accuracy & Prototyping

Designers and sample makers collaborate to refine facial expression, balance, and detail precision.

Two rounds of refinement are included for shape accuracy.

Average design-to-sample time: 5–7 days.

Material Sourcing & Fabric Development

Access to 500+ Plush Fabrics, Certified Dyes & Long-Term Mills

Delsney manages a robust material sourcing network built over 17+ years, connecting multiple mills for plush fabrics, threads, fillings, accessories, and packaging. Each Delsney project begins with a full review of tactile feel, durability, surface uniformity, color brightness, and compliance readiness.

Fabric Resources

Our material library includes：

300+ plush fabrics (short pile, long pile, crystal velvet, sherpa, DTY, minky)
45 embroidery thread families with 500+ color tones
6 filling types (PP cotton, sponge, rebound fiber, microbeads, custom blends)
Eco-grade materials for specific markets

Internal Fabric QC Data

Test Item	Delsney Passing Rate	Requirement
Colorfastness	96.7%	≥ Grade 4
Surface Pilling	98.1%	≤ Grade 3
Fiber Length Stability	97.3%	±0.5mm
Odor Level	99.6%	≤ Level 1
Heavy Metal Migration	100%	EN71-3 compliant

Supply Chain Strength

Partnered fabric mills maintain ISO-certified dyeing rooms
All color formulas are azo-free, suitable for EN71-3 testing
Mills produce stable lot-to-lot colors, keeping color deviation within Delta E ≤ 1.0
Delsney conducts random “4-point fabric inspection” before cutting

Plush Sampling & Prototype Creation

Fast, Accurate, Production-Ready Samples in 5–7 Days

1. Pattern Creation

Patterns are drafted according to 3-view drawings, considering：

Volume distribution
Curved seam logic
Filling chamber design
Hidden seam placement

Patterns go through two measurement verifications before cutting.

2. Fabric Cutting & Embroidery Test

Fabrics are cut manually for shape accuracy
Embroidery trials confirm stitch density (≥ 0.38 mm)
Backing materials adjusted to prevent fraying

3. Sewing & Internal Construction

Sample makers handle structural elements such as：

Mesh reinforcement
Cross-stitch anchoring
Neck support
Multi-layered felt integration for stability

4. Filling & Sculpting

Filling density is recorded per prototype:

Average density target: 0.23–0.28 g/cm³
Facial shaping and limb rounding done by hand
Fiber consistency checked throughout

5. Two Rounds of Refinement

Engineers and sample makers jointly refine：

Symmetry
Facial expression
Embroidery clarity
Limb proportion
Weight balance

Structural Engineering & Safety Optimization

Engineering-Based Adjustments to Ensure Durability & Compliance

1. Stress Point Reinforcement

High-risk points include：

Neck joints
Limb bases
Tail attachments
Wings
Accessory connection points

Reinforcement methods：

Mesh fabric layers
Invisible cross-stitches
Double bar-tack stitching
Backing boards for large plush pieces
Strategic stitch angles to distribute force

These reduce tear incidents by 82% in mass production.

2. Seam Engineering

Delsney maintains strict seam specifications：

Stitch spacing: 2.8–3.2 mm
Thread tension calibrated per material
Curved seams reinforced by micro-angle adjustments
Backstitching at all stress intersections

Every plush undergoes seam tensile checks before sealing.

3. Internal Support Architecture

For complex shapes or characters with large heads、thin legs、or extended limbs，engineers add：

Felt skeleton layers
Spinal stabilizers
High-density microfiber in strategic zones
Multiple filling chambers to maintain shape

This ensures long-term form stability.

4. Safety Radius & Detachable Risk Control

Accessories, noses, and decorative elements are tested through：

Pull force ≥ 70N
Smoothness index Level 1（finger-friction test）
Double-anchored installation

No detachable components are allowed for infant-grade products.

5. Pre-Compliance Adjustments

Before EN71、ASTM F963、or ST testing, engineers review：

Pile length
Flammability behavior
Internal reinforcements
Embroidery density
Material chemistry records

This preparation significantly reduces testing failures and retest costs.

Embroidery & Detail Processing

Precision Facial Features, Logos & Decorative Elements Engineered for Clarity & Safety

Embroidery is one of the most defining elements of plush identity—eyes, expressions, brand logos, patterns, and signature details. Delsney runs a dedicated embroidery workshop equipped with:

12 high-precision embroidery machines
4 embroidery file engineers
500+ thread colors
Azo-free & EN71-3-compliant dye sources

1. Stitch Density Calibration

Every design undergoes density mapping：

Standard density: 0.32–0.38 mm
Thin-line density: 0.28–0.31 mm
Large-area fill density: 0.40–0.45 mm

Density affects the clarity, durability, and safety of the embroidery. All facial elements must withstand 600+ rub cycles without deformation.

2. Thread Tension Management

Thread tension varies by:

Fabric stretch
Fiber direction
Pile length
Embroidery shape

Delsney’s technicians adjust tension per color segment to avoid distortion.

3. Backing & Reinforcement Material

All embroidery areas use 2–3 layers of fiber backing to prevent:

Thread pull-outs
Edge fraying
Inner-fiber leakage

Backing width minimum: 3–5 mm depending on size.

4. Color Matching Accuracy

Delsney maintains a thread color deviation index of Delta E ≤ 1.0 for repeat orders. Engineers reference Pantone or provided HEX/RGB color codes for consistent results.

5. Safety Review

Embroidery for infant and toddler products must pass：

Anti-fray test
Stretch test
Dry & wet rub test
Saliva simulation test

No chemical softeners are used in embroidery processing.

Quality Control & Production Management

20+ QC Steps, Cross-Factory Standards & High-Consistency Manufacturing

01

Material QC

Colorfastness test
Pile direction alignment
Fiber uniformity inspection
Accessory pull-force check

Only approved materials move to cutting.

02

Cutting QC

Pattern accuracy tolerance: ≤ 2 mm
Left-right symmetry checks
Waste control tracking

Cutting boards are documented for each batch.

03

Embroidery QC

Color consistency
Line thickness verification
Backing stability
Thread tension check

Rejection rate here is kept under 1.8%.

04

Sewing QC

Stitch length check (2.8–3.2 mm)
Seam strength pull test
Critical point reinforcement check
Limb symmetry audit

All sewing workers follow a needle ID tracking system.

04

Filling QC

Density measurement
Facial sculpting accuracy
Limb contour shaping
Weight balance test

Average plush weight deviation kept within ±3%.

04

Final QC

Full visual inspection
Dimensional measurement
Embroidery clarity
Packaging alignment
Label verification
Export carton check

Yearly production consistency target: ≥ 97.5% across all batches.

Safety & Compliance Integration

Delsney incorporates international safety standards into every stage of development instead of waiting for post-production adjustments.

Our compliance department maintains updated guidelines for:

EN71-1, EN71-2, EN71-3
ASTM F963
CPSIA
Japan ST Standard
AS/NZS ISO

Compliance Integration Process

Pre-Compliance Engineering Audit

During sampling, engineers identify：

Potential small-part risks
Accessory attachment concerns
Pile length flammability issues
Fiber migration probability
Reinforcement needs

Adjustments are made before third-party testing.

Material-Level Compliance

Materials must pass：

Heavy metal check
Azo dye check
Odor level test
Color migration test

Delsney keeps certificates for every material batch.

Documentation Prepared for Testing Labs

We assist with：

Material composition sheets
Dye source records
Embroidery material details
Batch inspection photos
Tracking label references
Production month records

This reduces approval time for SGS, Intertek, BV, TÜV.

Internal Flammability & Stress Pre-Tests

Performed before lab submission:

Quick burn test on both pile & base
Seam tensile check
Accessory: pull-force ≥ 70N
Embroidery friction resistance ≥ 600 cycles

Pre-testing improves first-pass success rate significantly.

Ongoing Compliance Monitoring

For repeat orders, Delsney：

Re-checks material batches
Updates safety logs
Monitors chemical suppliers
Tracks any regulatory changes

Compliance is a continuous process, not a one-time activity.

Packaging, Labeling & Export Preparation

Safe, Compliant, Retail-Ready Packaging for Global Distribution

Delsney’s packaging workflow is designed to meet the requirements of international logistics, retail shelves, and safety compliance audits. Each production batch passes through a dedicated packaging line operated by 10+ trained workers, with oversight from QC and compliance teams.

Key Packaging Capabilities

Age-Grading & Label Placement

Labels are positioned based on market rules:

3+ symbol for general children’s plush
0+ symbol for infant-grade plush
Warning icons placed at visible corners
Tracking labels for US orders
EN71 marking alignment for EU shipments

Every label layout is recorded and archived with batch photos.

Polybag Safety Standards

Delsney uses export-grade bags:

Thickness ≥ 0.03 mm
Printed suffocation warnings for US/EU
Anti-fog or clear-HDPE options
Heat-sealed edges to prevent tearing

Each batch undergoes seal strength tests.

Retail Packaging Options

We support:

Full-color printed boxes
Window boxes
Gift boxes
Eco-friendly kraft packaging
Barcode + SKU printing

Inks meet RoHS / REACH requirements.

Export Carton Standards

Outer cartons follow:

Strength rating: 5-ply or 7-ply
Load capacity: 38–42 kg
Humidity resistance: 12–18 hours
Drop test: performed on 10% of monthly batches

Cartons are labeled clearly according to customer country requirements.

Batch Documentation

Each export order includes:

Packaging photos
Label map
Carton measurements
Weight list
Packing list for customs

This shortens customs clearance time.

Logistics & Global Shipping Support

Export-Ready Shipping From China to 86+ Countries

Delsney manages logistics with the same precision as production.
Our team supports global shipments for brands, wholesalers, IP studios, and retail programs.

Freight Coordination

We assist with：

Sea freight (FCL / LCL)
Air freight for urgent shipments
Express delivery for samples
Door-to-door international forwarding
Amazon FBA inbound shipments

Average export volume：18–22 containers / month.

Shipping Documentation

Delsney prepares:

Commercial invoice
Packing list
HS code confirmation
Certificate of origin (if needed)
Customs declaration paperwork
Safety certifications for regulated markets

This minimizes delays during customs inspections.

Palletizing & Secure Loading

For shipments requiring enhanced protection:

Pallet height standardized：≤ 1.3 m
Shrink-wrapped pallets
Protective corner boards
Load-balanced arrangement inside containers

Loading photos are provided to customers for verification.

Delivery Timeline Planning（Typical shipping times from Shenzhen port:）

Region	Transit Time
USA West Coast	15–18 days
USA East Coast	28–32 days
Europe	28–35 days
Japan / Korea	3–5 days
Australia	12–16 days
Middle East	20–25 days

Shipment Tracking Assistance

Our logistics team provides:

Booking updates
Vessel information
Real-time container tracking
Delivery appointment support for distributors & FBA

After-Sales Support & Reorder Management

Every plush program managed by Delsney is supported long term. Reorders are handled with high repeatability due to our documentation, version control, and archived production data.

After-Sales Support Capabilities

01

Production Record Archiving

For each order, we archive for 3 years：

Material batch codes
Pattern versions
Embroidery files
QC photos
Packaging layouts
Compliance records
Production month / workshop data

This archive allows seamless reorders without re-explaining details.

02

Reorder Accuracy

Delsney achieves:

Color deviation ≤ Delta E 1.0
Weight deviation ≤ ±3%
Dimension deviation ≤ 3 mm
Accessory matching accuracy ≥ 98%

Perfect for long-term brand product lines.

03

Issue Handling & Replacement

In rare cases of product defects：

QC team investigates root cause
Corrective actions implemented
Replacement units produced when necessary
Report provided with evidence photos

Defect rate maintained at <0.6% annually.

04

Continuous Improvement

Based on client feedback and QC reports, Delsney improves：

Reinforcement points
Stitching patterns
Filling density
Packaging strength
Material selection

These improvements are applied to future batches automatically.

Frequently Asked Questions

Q1: What information is needed to start a plush project with Delsney?

A sketch, artwork, reference photo, or 3D model is enough for our engineers to begin technical evaluation. We convert visuals into manufacturable files, prepare 3-view drawings, recommend suitable plush materials, and outline sizing, structure, and safety considerations based on your market. The more reference details you provide—such as preferred fabric feel, target size, or functional details—the faster we complete the initial assessment.

Q2: How long does sampling usually take?

Most plush samples are completed within 5–7 days, as our dedicated sample studio handles pattern creation, embroidery tests, sewing, internal reinforcement, and filling adjustments all in-house. Complex plush with layered accessories, large embroidery zones, or highly intricate shapes may take 7–10 days, but our engineers always communicate timelines clearly and provide progress photos during development.

Q3: What is Delsney’s mass-production capacity?

Production output varies by plush complexity, but standard plush lines produce 7,000–15,000 units per day across 14 sewing lines, while high-detail plush typically reaches 5,500–10,000 units daily, and oversized plush ranges from 1000–3,000 units. Stable production records, shift management, and experienced line supervisors allow us to maintain consistent productivity throughout the year.

Q4: Does Delsney support licensed IP projects?

Yes. Delsney frequently produces plush for licensed characters, event mascots, collectible programs, and influencer brands. We maintain strict file protection, internal confidentiality protocols, and controlled-access engineering workspaces. Our teams understand expression accuracy, brand guideline adherence, and long-term series consistency, making us suitable for ongoing IP or multi-season programs.

Q5: How does Delsney maintain consistent quality across orders?

Quality consistency is achieved through 20+ QC checkpoints, pattern version control, embroidery file management, batch-level photo documentation, and material record archiving for at least 3 years. Reorders follow the exact original specifications, ensuring color deviation stays within Delta E ≤ 1.0, weight variation remains within ±3%, and dimensions maintain a tolerance of 2–3 mm.

Q6: Can Delsney support EN71, ASTM F963, CPSIA, and ST compliance?

Yes, our compliance engineers evaluate structural risks, material chemistry, embroidery durability, and accessory strength before samples go to third-party labs. We provide composition sheets, dye records, tracking-label details, and QC logs to support testing at SGS, Intertek, BV, or TÜV. Most programs pass on the first submission because design and material risks are addressed early.

Q7: How does Delsney source and verify plush materials?

Delsney works with long-term mills that supply over 500 plush fabrics and 600 embroidery threads, all tested for colorfastness, odor level, fiber stability, and heavy metal safety. Materials undergo internal inspection before cutting, ensuring only stable and safe raw materials enter production. Dye sources are azo-free and aligned with EN71-3 chemical limits.

Q8: What is the typical lead time for mass production?

Most plush orders require 18–28 days depending on quantity, structure, and packaging requirements. Projects involving retail boxes, large embroidery areas, or special accessories may take 28–35 days. Production supervisors maintain weekly schedules and report updates to ensure timelines stay stable even during peak seasons.

Q9: How are logistics handled for international shipments?

Delsney coordinates sea freight, air freight, express delivery, and Amazon FBA inbound shipments. Documents including invoices, HS codes, packing lists, and certificates of origin are prepared by our logistics team. We export around 18–22 containers per month, and clients receive container-loading photos and tracking updates for every shipment.

Q10: What happens if there are issues after a shipment arrives?

If any product concerns appear, our QC team reviews photos or videos, identifies the cause, and applies corrective actions. In rare cases requiring replacements, new units are produced promptly. With defect rates below 0.6% annually, Delsney’s after-sales team keeps communication clear and supports long-term brand stability.

Build Your Plush Program With Delsney

Partnering with Delsney means working with a manufacturing ecosystem refined through 18+ years of engineering discipline, structured QC, and factory specialization. Our plush production infrastructure includes 14 sewing lines, a sampling studio run by 8 experienced makers, a material library of 500+ plush fabrics and 600+ embroidery colors, and a QC department of over 20 inspectors who oversee more than 20 checkpoints from material arrival to final packaging. Delsney supports programs for original characters, licensed IP, influencer merchandise, seasonal collections, and collectible retail lines. With reliable communication, precise engineering, and stable factory output, Delsney ensures each production stays consistent and globally compliant.