But now we can se exactly how stuffed animals are made. The actual process can vary from company to company. There is also a differen way to fill the stuffies.
It greatly depends on the size of the stuffies too. It all starts with placing a few layers of the main material of the stuffies on a big table. Then, using a special form, the fabric is cut into the various shapes of the future stuffed animal. Usually lots and lots of exact pieces are cut in order to make a large quantity of the same toy.
The forms are made by specialists who trace the patterns made by the designers when designing the toys. The stuffies start their lives as a drawing.
When the pieces are cut, they are sent to the embroidery department where a special computerized machine embroids the needed details on dozens of pieces at once.
The ready pieces are then sent for machine sewing. This is usually done by employees with professional sewing machines. Another department then takes the pieces and turns them inside out to the correct side.
Then the toys are sent for stuffing. For smaller stuffed animals the stuffing is added by hand. Really big stuffies though are usually filled with a special machine.
The almost finished stuffed animals are then weighed. If they don’t weigh within specifications, they are sent back to add more stuffing or remove some. Then the last seam is sewed and the stuffie is virtually done.
It will undergo Quality Control to ensure all the parts are correct and there are no mistakes or flaws. Then they are usually run through a metal detector to be sure no needle or something else dangerous has fallen into the toy. Finally, the stuffies are packed and shipped out to the stores where we usually meet them for the first time.
Here are two great videos on how stuffed animals are made:
And the second one: