Most knitting and crochet toy patterns simply tell you to stuff the body. I am guilty of this myself. But what you stuff your toy with and how you stuff it can have a significant impact on the overall look and life of a toy. Lumpy stuffing, over stuffing and improper washing can ruin hours of work hand making a toy.

First let's look at what you are stuffing your toy with. Each stuffing material have advantages and disadvantages to consider before you stuff.

Polyfill

The jack-of-all-trades of stuffings is also the most widely available. Polyfill is light weight and has great memory so it bonces back even after a fierce hugging session. Because it is made from plastic it is machine washable making it a great choice for a young child.

Polyfill is a great beginners material because it clumps much less than many of the other stuffing options. It is prefect for large to medium size toys and the bodies of smaller toys. However when used in a small or detailed area it is very easy to result in overstuffing.

Bamboo

Bamboo filling is relatively new to the craft market and it is billed as an environmentally friendly alternative to polyfill. It is not as widely available yet because there are a limited number of manufacturers. The two materials have some very different properties however, bamboo does not bounce back as well as polyfill and tends to clump more. These same properties make it great for more detailed areas in a toy. After a firm stuffing, bamboo has an almost sculptural quality and holds its shape beautifully making it the perfect choice for heads, hands, arms, tails, etc. Slightly over stuff bamboo and then apply pressure from the outside of the toy. The fiber will move almost like clay in your hands.
 
Special care is needed when washing bamboo toys because the fibers tend to clump when wet. The manufacturer recommends spot cleaning toys and this is the best method but if you have a heavily soiled toy try soaking it and then allowing to air dry.

Plastic Pellets

The heaviest of the stuffing materials, plastic pellets are mostly used in small amounts in key areas. Adding them to the ends of arms and legs pellets will give your toy a more floppy feel. When added to the butt you have a much better chance of getting your toy to sit without falling over. If you are feeling nostalgic for 90s toys you can stuff the whole toy loosely with pellets for an extra floppy toy.

Plastic pellets can be a little hard to find and it is tempting to use dried rice or beans as a replacement. Rice and beans, however, can start to rot over time especially when exposed to moisture. If you are desperate for a replacement try heading to the sporting goods store for some plastic BBs.

Because pellets are small they are considered a chocking hazard for children under 3. Be careful when crafting with them. For knit and looser gauge crocheted toys, consider sewing them in a fabric bean bag before stuffing them into the toy.

Shredded Foam

Shredded foam is a byproduct of manufactures that cut foam such as furniture manufacturers. This makes it a somewhat environmentally friendly product. However depending on the manufacturers, the product can vary form greatly. In general foam is firmer and heavier than polyfill but lighter and more yielding than bamboo. This makes it great for larger toys that can be used as pillows or for lounging on. The bounce back on the foam is a little slower than other fillings making making it less than ideal for smaller toys. Depending on the toy and your sense of humor, the 30 seconds to the head to re-inflate can be hilarious or macabre.

Wool

Wool is a traditional stuffing material that has fallen out of favor but is making a comeback. Like foam it can vary a lot depending on the type of sheep and how it is processed. It has great sculptural qualities like bamboo but is light like polyfill. Unfortunately, there are a few drawbacks. Wool is significantly more expensive than polyfill and it is not hypoallergenic. It is also not machine washable with the exception of superwash wool.

Tips for Better Stuffing

Now that you know what you are working with, here are a few tips to help you use your materials more effectively.

1. Don’t bunch up your stuffing

While it might feel like the most natural thing in the world when trying to fit a lot of material through a small opening, wading up the stuffing will cause lumps. Use your finger or other handy tool to slowly poke the stuffing through trying to keep the edges raw so each piece will cling to each other.

2. Use as few pieces of stuffing as possible.

The best way to prevent your toy from becoming a lumpy mess is to have as few breaks in your stuffing as possible.

3. Think about how the toy will be squeezed.

Another way to fight lumps is to try to place the breaks between your handfuls of stuffing as close to perpendicular to the direction that the toy will be squeezed as you can. So, if you are stuffing a tall, vertical body it will most likely be squeezed horizontally. This might make a horizontal break between two handfuls of stuffing to separate leaving an unattractive gap. If you try to keep the break between the stuffing as close to vertical as you can the two handfuls of stuffing are not likely to separate. The same principle applies to places where the toys narrow like the neck. If you have a break in your stuffing right at the neck line, after a few hours of play the filling will likely separate and you will have a floppy headed toy.

4. Don’t be afraid to mix materials

When looking at the materials, it is clear that each has its advantages and disadvantages. There is no rule that says you have to only stuff with one material. You can use bamboo for arms and legs and polyfill for the body. Experiment and find what works best in the toy you are making.

5. Don’t be afraid to start over

Sometimes you don’t get it right the first try, it is not the end of the world to rip out the stuffing and try again. You spent the time stitching to toy, you deserve to have it look its best.