Soft Foam Home for Kids – Trusted OEM/ODM Partner Since 2013

Production Process

Our production process follows strict high standards, with each step carefully controlled to ensure that our sofas and soft play products achieve excellence in safety, comfort, and durability. Below is a detailed breakdown of our process.

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Raw Material Inspection & Pre-Treatment

Before production begins, all incoming raw materials undergo strict inspection and quality testing to ensure that fabrics, foam, and other accessories meet environmental and safety standards.

Material Inspection

Fabrics and foam are tested for quality, and each batch is labeled for traceability.

Pre-Treatment

Fabrics undergo pre-shrink processing, while foam and soft play materials are cleaned, disinfected, and pre-shaped to ensure optimal processing conditions.

Simultaneous Pre-Treatment & Cutting

Fabric Cutting

High-precision automatic cutting machines are used to precisely cut various eco-friendly fabrics (such as glow velvet, corduroy, and teddy velvet). This ensures consistent dimensions, patterns, and clean edges.

Foam Cutting

Advanced cutting equipment is employed to shape foam according to standard dimensions and custom designs, ensuring uniform filling and stable density for optimal comfort and durability.

Pre-Treatment for Soft Play Materials

For soft play products, specialized foams or rubber materials undergo pre-molding processes to create a perfect foundation for seamless assembly.

Sewing

Automated sewing machines and skilled workers are employed to stitch fabric covers, ensuring each seam is neat, strong, and durable.For soft play products, in addition to external fabric covers, special stitching and decorative seams are applied to enhance both aesthetics and durability.

Quality Inspection

Multiple quality control checkpoints are set throughout the production process to ensure each product component meets high-quality standards.

Fabric Cover Inspection

Thread Check:Ensuring no loose threads for a clean and refined appearance.

Durability Test:Conducting tensile tests to confirm strong and secure stitching.

Zipper Inspection:Checking smoothness and ease of operation for seamless functionality.

Foam & Soft Play Material Inspection

Foam Check:Inspecting for stains, accurate dimensions, and damages while using a density tester to ensure uniform filling.

Soft Play Testing:Conducting pressure, torsion, and modular connection stability tests to verify the product maintains its shape after repeated use.

Final Finishing & Function Testing

Before assembly, each product undergoes a final finishing process to ensure a polished and professional appearance. This includes removing excess threads, eliminating lint, and attaching brand labels and anti-counterfeit markings.

Function Testing:

For products with modular, foldable, or multifunctional designs, rigorous tests are conducted to verify seamless folding, assembly, and storage functions, ensuring optimal performance in real-life use.

Assembly

After all the previous processes, the cloth cover, sponge, and other accessories are precisely assembled to form the final product.For soft play products, special attention is paid to the stability and flexibility of the connection between the modules to ensure that the overall structure is firm and easy to change and combine.

Compression and packaging

After assembly, advanced compression equipment is used to compress the product volume to about 20% of the original volume for easy transportation and storage.

Ultimate packaging

After compression, the product is packaged externally, including product instructions, safety warnings and brand promotion information.

Logistics preparation

After product packaging, the inventory management and logistics scheduling stage is entered to ensure safe transportation.

Logistics preparation and shipment

After the product is packaged, it enters the finished product storage and logistics scheduling stage.Arrange appropriate transportation methods to ensure that the product is not damaged during transportation and is delivered to the customer in a timely manner.

Data recording and tracking

Record the production data of each process, including raw material batch, production date, quality inspection data, etc., to ensure rapid tracing when problems arise.

Use modern information management system to track each product throughout the process to ensure product quality and customer satisfaction.

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Introduction to automation equipment

Automatic cutting machine

The high-precision automatic cutting machine ensures accurate fabric cutting and provides a reliable foundation for subsequent processing.

Automatic cutting machine

The high-precision automatic cutting machine ensures accurate fabric cutting and provides a reliable foundation for subsequent processing.

Automatic cutting machine

The high-precision automatic cutting machine ensures accurate fabric cutting and provides a reliable foundation for subsequent processing.

Tender Unlocking More Joy Every Day

We have a professional product design and R&D team. Whether you just have an idea or already have a product drawing, we can quickly realize your idea and create a product prototype.