The Plushie project started as an investigation into how simple geometric forms can be translated into soft goods while retaining their structural integrity. The design process relied heavily on creating complex pattern pieces that, when sewn together, allow for a clean, rounded shape without relying on excessive internal stuffing. This required a deep dive into fabric tension and seam stress-testing, ensuring that the toys could withstand daily handling while maintaining their intended volume and shape over time.

I spent significant time mapping the interaction between different material weights-pairing heavy-duty base fabrics with lighter, higher-pile exteriors-to create a distinct sensory experience. The challenge was maintaining manufacturing scalability; every piece had to be designed so that it could be assembled using standardized industrial sewing techniques. The end result is a collection that feels bespoke but is engineered for consistent, high-volume production, ensuring that each unit looks identical to the initial prototype.