How are plush toy factory toy samples made?

Plush Toy Sample Production:

Once the requirements for the original prototype are identified, materials and manufacturing methods specific to the prototype are selected. For prototypes requiring cutting, knife molds are created; for those needing hot plush, hot melt plates are made; for prototypes requiring pattern cutting, polyester pieces or screen printing plates are produced. Prototypes for computer embroidery are distinguished between full embroidery and patch embroidery. Tasks such as knife mold creation, computer embroidery, or screen printing are delegated to relevant departments, while normal cutting requires prototype preparation based on specified requirements.

Prototype Materials:

• Original prototypes use 200g cardboard.

• Production prototypes use 0.8mm elastic paper.

Prototype paper should be flat, clean, and dry.

Prototype Guidelines:

When creating plush toy prototypes, adhere to principles such as straight lines, curves, angles, proportions, symmetry, and positioning. Text descriptions should be on the front of the prototypes. These principles mean that straight lines should be straight, curves should be smooth, and knife holes precise, while angles and proportions should be consistent. Prototypes with central lines, such as trapezoids, should maintain symmetry on both sides, and opposite sides of rectangular prototypes should have parallel straight lines. Ensure accurate positioning points, and for joining or saving fabric, ensure corresponding, complete positioning marks.

Prototype Tolerance:

For replication of production prototypes, precision is crucial to match the original prototypes. Prototypes under 10cm in length must have no deviation, while those above 10cm typically have a deviation within 0.5cm. To maintain prototype accuracy, inspect for deformation and frequently cross-check with the original prototypes during use. Promptly replace any damaged or distorted prototypes. When fabric shrinkage occurs after cutting due to different materials or processes, consider enlarging the prototype, but only after confirmation through sealing.

Prototype Marking Requirements:

Effective prototype markings are vital for proper identification. These markings include product model, product name, part name, and prototype number, along with material name (processing requirements), silk flow direction, piece count, and positioning marks. All these details should be marked on the prototype. If the prototype’s area is too small to include all details, mark the prototype number and reference the process technical requirements sheet. Ensure corresponding content is available on the process technical requirements sheet. Mark controlled indications on the prototypes; cover original prototypes with the technical department’s control seal and production prototypes with the production department’s control seal. Control seals should feature the name or code of the person sealing the sample.

Replicated Prototype Quality Requirements:

The precision of replicated production prototypes is essential to guarantee accurate cutting. Quality requirements for replicated prototypes include precise shape, correct markings, and complete information.

Understanding the Cutting Layout:

A cutting layout provides a schematic representation of how each prototype piece should be positioned to minimize material use. It typically indicates silk flow or direction, whether prototypes should be nested or aligned in the same direction, and general information about nesting prototypes. When cutting, calculate and arrange prototypes based on the information in the cutting layout, considering production batch requirements, to determine the unit cutting quantity. Cut in a manner that minimizes material consumption.

Using Digital Instruments or Industrial Photography for Prototype Layout Conversion into Vector Graphics:

Prototype layout is increasingly digitized. A digital instrument, widely used in various professional applications, comprises an electromagnetic induction board, cursor, and corresponding electronic circuits. Users move the cursor to a specific position on the electromagnetic induction board, align the crosshair intersection with the digitized point, and press a button to organize the corresponding command symbols and coordinate values into ordered information. This information is then transmitted to the main computer through an interface (often a serial interface). Essentially, a digital instrument is a large-area handwriting tablet, where users can draw graphics with a specialized electromagnetic pressure-sensitive pen or light pen and transmit it to a computer system. However, it differs significantly from a standard graphics tablet in terms of software support and hardware design.