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When it comes to customizing plush toys, appearance is only half the story—what's inside matters just as much. Whether you're creating a cuddly mascot, a branded character, or a promotional giveaway, the choice of stuffing material plays a crucial role in determining the toy's softness, texture, durability, shape retention, and overall cost. In this guide, we'll walk you through the most popular filling materials used in today's plush toy manufacturing,and help you decide which one best fits your custom plushie project. This resource is especially valuable for international buyers, designers, distributors, and creators aiming to craft high-quality plush toys tailored to specific markets and user needs.
Why Plush Toy Filling Matters
Many of our global clients ask:
“What's the softest stuffing you have?”
“How do I keep my plush toy from losing its shape over time?”
“Can I make a weighted plush for sensory use?”
“Is this filling safe for babies or toddlers?”
“I want the plush to be squishy but not too floppy — what should I choose?”
All these questions have one thing in common: stuffing.
The type of stuffing inside a plush toy determines whether it feels squishy or firm , how it holds up to use and washing, and whether it's suitable for different age groups or markets. For example, a premium baby plush might need a softer, non-clumping fill, while a large event giveaway may prioritize shape and affordability.
Let's explore the most common types of stuffing used in custom plush toys today！
1. PP Cotton (Polypropylene Fiberfill)
Soft | Lightweight | Cost-effective
PP cotton is the most widely used and budget-friendly filling for plush toys. Known for its soft, fluffy texture, it creates a cozy and squeezable feel that’s loved by children and adults alike. However, not all PP cotton is created equal—its characteristics depend largely on fiber fineness, measured in Denier (D):
0.8D / 0.9D: Ultra-fine fibers that are exceptionally soft and plush—ideal for premium plush toys and baby products.
1.2D – 1.5D: A balanced option offering both softness and affordability—perfect for general plush production.
3D / 7D / 15D: Coarser, more supportive fibers that offer better shape retention and lower cost—suitable for large-scale toys or structured designs.
✅ Best for: Standard stuffed animals, promotional giveaways, soft dolls, and cost-sensitive bulk orders.
Pro tip: The finer the fiber, the softer and more luxurious the finish—but expect a slightly higher price.
Bouncy | Fluffy | Excellent Shape Retention
Named for its unique structure—tiny round fiber clusters that resemble pearls. Pearl cotton is lightweight, ultra-fluffy, and naturally elastic. Compared to standard PP cotton, it resists clumping and maintains its volume even after repeated washing, making it a premium choice for plush toys that need to retain their shape over time.
Ideal for plush designs that need to maintain their shape.
Has a full and cloud like texture.
Higher loft and superior bounce, not prone to clumping and sagging.
✅ Best for:High-end plush characters, decorative plush products, and branded plush toys that require a premium tactile experience.
Ultra-Soft | Cloud-Like | Bouncy
Down cotton is a synthetic alternative that replicates the luxurious softness of natural down—without using any animal products. Unlike real down, it's cruelty-free, machine-washable, and resilient, making it ideal for plush toys that demand both comfort and durability.
Delivers an exceptionally smooth, squishy, and cloud-like feel.
Excellent bounce and loft retention—won't flatten over time.
Hypoallergenic and safe for infants and sensitive skin.
✅ Best for: Baby plush toys, infant rattles toy, sleep companions, sensory plush items, and premium comfort plush collections.
Want a plush toy that feels like Squishmallow? This is your best choice!
Supportive | Slow Rebound | Durable
Memory foam provides a firm, slow-rebounding touch, making it an excellent choice for plush items that require support, such as plush cushions or ergonomic plush toys. While it's not as commonly used as other fillings, it's a fantastic option when your design demands structural integrity and comfort.
Offers firm support and maintains shape, ideal for plush toys that need to sit upright or hold a specific form.
The slow rebound effect gives a unique, "hugging" feel, providing a comfortable and ergonomic experience.
Helps to retain the structure of the toy for long-lasting durability.
✅ Best for: Ergonomic plush toys, travel cushions, posture-support products, and plush designs requiring shape retention.
Down Cotton
Pearl Cotton
Memory Foam
Safe | Protective | Essential for Regulated Markets
If you're selling plush toys in Europe, the UK, or other markets with stringent safety regulations, fire-retardant cotton is essential to meet EN71 and BS5852 standards.
Also known as "EN71 stuffing," "flame-resistant plush filling," and in China it is called "British standard flame retardant cotton", this material adds an extra fire resistance, making it ideal for toys intended for children, educational institutions, hospitals, public giveaways, or licensed merchandise.
1. Meets safety requirements for regulated markets.
2. Provides added protection and peace of mind for parents, schools, and organizations.
3. Often required for products that need to meet official safety certifications.
✅ Best for:
Custom plush toys for the European and UK markets
Kid Plush dolls for schools, clinics, and public venues
Toys requiring EN71 or UKCA compliance
OEM plush projects for brand retailers needing safety documentation
While soft fillings like PP cotton or down cotton define the plush toy's overall softness and volume, supplementary fillings and interactive components can greatly enhance the toy's functionality, texture, and user experience. These elements are especially valuable in custom plush toys, weighted sensory plushies, and pet toys.
Supplementary fillings allow plush toys to:
Serve sensory or therapeutic purposes (e.g. weighted plushies)
Enhance play value (e.g. sound modules, squeakers)
Improve visual or tactile interest (e.g. scented beads, flowing foam beads)
Support niche functions (e.g. inflatable plush, warming elements)
By combining core stuffing materials with targeted add-ons, manufacturers can tailor plush toys to meet the expectations of diverse markets—from children’s toys to pet products, promotional gifts, and even home décor plush.
Supportive · Lightweight · Cost-effective
Foam is a budget-friendly alternative to memory foam when shape support is needed. It’s often used in plush toys that require structured areas, such as feet, heads, or plush backpacks. Compared to memory foam, sponge offers reasonable firmness while keeping costs lower.
Best for:Cost-sensitive custom plush toys needing form retention.
Also known as snow beans, bean bag beads, or expanded polystyrene (EPS), these ultra-light particles are round, soft, and breathable. They create a flowing, adaptive feel and are often used in bean bag plush toys, DIY kits, or plush cushions. The beads adjust to room temperature, offering comfort year-round.
Best for: Bean bag plushies, large plush cushions, plush chairs.
A versatile bead filling often used for weighted plush toys. These plastic beads can also come scented, adding an aromatic element to the toy. Their smooth surface and consistent size make them ideal for achieving a subtle, pleasant weight.
Best for: Weighted plushies, scented plush toys.
Heavier than PE beads, glass beads provide more substantial weight and are commonly used in high-end weighted plush toys or sensory therapy toys. Their tiny size and smooth finish ensure a premium feel.
Best for: Weighted plushies, scented plush toys, therapeutic plush toys.
Maifan stone is often used when heat retention or temperature stability is needed. This natural mineral material is preferred in plush toys designed for warmth or mild thermal application.
Best for: Microwavable plush toys, plushies designed for heated use.
Foam Beads
Scented Particles
Glass Beads
Heatable particles
In recent years, inflatable plush toys have become a trendy option. These toys feature a plush fabric shell with an internal air bladder, combining the softness of plush with the novelty of inflatable products. They’re ultra-lightweight and eye-catching—ideal for promotions or gifts.
Best for: Inflatable plush toys, novelty gifts, travel plushies.
These air-press modules make a squeaky sound when pressed and are frequently used in plush pet toys or baby soft books. Durable and fun, they enhance interactivity.
Best for: Pet plush toys, infant sensory toys.
A small module that mimics a real heartbeat, commonly used in pet calming plush toys to soothe anxiety. Also popular in customized gifts with emotional value.
Best for: Pet comfort toys, emotionally themed plush gifts.
These are battery-powered voice modules that can be customized to play specific sounds, songs, or voice messages. Great for personalized plush toys, gift plushies, or branded promotional items.
Best for: Talking plush toys, personalized gifts, promotional plush.
Inflatable plush toy
BB Squeakers
Heartbeat Simulators
When customizing your own plush toy, be sure to consider:
Intended use – Will it be hugged, displayed, used for sleep, or provide sensory comfort?
Target audience – Children, adults, collectors, or people with special sensory needs?
Budget – Some materials offer a premium feel but come at a higher cost.
Regulatory requirements – Especially for markets like the EU, UK, or US (EN71, ASTM, etc.).
Stuffing is more than just fluff—it's the heart of your custom plush toy. Choosing the right material ensures your plushie toy feels right, lasts long, and suits your brand's purpose.
At Hebei Yerong Trading Co., Ltd, we help clients around the world create personalized plush toys with the perfect combination of design, stuffing, and market appeal. From soft and cuddly baby toys to firm, structured novelty plush—we bring your ideas to life with the right materials.
