Once you have mastered the thought that safety must come first, every stitch you make, takes on a whole new light. Something as simple as a button for an eye on a Teddy bear could be a potential choking hazard if it is not properly attached. If a button is necessary, use button and carpet thread and a small button in the inside to anchor the "eye" button. Do not skimp on the number of stitches you make. When ever possible, try to use an applique or embroidery for an eye so there is no possibility of the choking hazard a button can create. (Sewing Buttons and Buttonholes
Many years ago, my daughter was innocently playing with one of those stuffed animals you win at county fairs. We all know the type, with the glued on eyes and mouth. I turned my back for just a minute and heard her gagging. The "mouth" had come off the animal and was stuck in her mouth. Never use just fusible on a child's toy. You can place the item using fusible, but be sure to finish the job with applique methods, such as a satin stitch.
Years ago there was a recall due to stuffing material being flammable. Our government has taken steps to make sure this can't happen today and you must do the same when you are making a toy. I have seen people suggest saving up serger trimmings to stuff toys. There are a few reasons I tend to disagree. First, these shavings are lint laden and the increase in asthma among children, does not make this a worth while savings in my mind. Second, there is a chance that these shavings will have machine residue and could cause problems. Thirdly, these shavings are not going to give you a smooth stuffed finish.
I recommend using a excellent quality poly stuffing. It may be tempting to buy the less expensive brand but it has always been my experience that these tend to clump. Say you are stuffing an animal head, start with a large clump of stuffing and spread it out towards the fabric, add more stuffing to the middle and spread it again. Keep repeating this procedure until you reach the firmness you desire. This will prevent a clumpy appearance that can show through in a very short period of time. Distribute stuffing in to corners and hard to reach places like ears, bu using a semi-sharpened dowel as described in Tips and Tricks to Sew Corners.
When you are making a stuffed toy, there is always an area that must be slip stitched to close it. Always use tight, small stitches sewn with quality thread. As an extra precaution, hand stitch the opening twice, so that if one thread does come loose or break, there is a back-up holding the stuffing inside.
Dressing a toy doll or animal can create un-thought of dangers. Belts, neck ties and shoe laces must be anchored to the toy and they can not be long enough to present a strangulation hazard. If something is long enough to present a strangulation hazard when it is un-tied, take the time to anchor the tie with hand stitches. Strong thread and well anchored stitching can prevent a future problem.
Always keep safety first on any and every thing you sew for a child!
