Why the filling deserves as much thought as the fabric

Most makers spend hours choosing the perfect cotton print or brushed flannel, then reach for whatever stuffing happens to be in the basket. That is a shame, because the filling decides how a toy feels in a child's arms, whether it survives a 40°C wash after a nursery bug, and how long it stays plump instead of sagging into a lumpy, sorry shape. It also accounts for a fair slice of the environmental footprint of a handmade piece, especially if you are sewing a batch for a craft fair or a school fete. The good news is that there is no single "best" filling, only the right one for the make in front of you.

Recycled polyester: the dependable everyday choice

Recycled polyester is the workhorse of soft toy filling. It is usually sold as hollow fibre or, better still, as cluster fill, where small scrunched balls of fibre are heat-set so they stay separate rather than matting together. Look for a Global Recycled Standard logo on the bag; roughly twenty plastic bottles are diverted from waste for every kilo of stuffing produced.

In practical terms it is hard to beat. It is springy, holds loft well, costs around £8–12 per kilo, and takes a 40°C machine wash without complaint. Cluster fill dries overnight and barely clumps. The caveats are honest ones: it is still plastic, it sheds microfibres in the wash (use a guppy-style bag), and it can feel warm and slightly clammy against a baby's cheek. It also has a low melting point, so keep the iron well away. Tamp it in small handfuls rather than one big lump, and aim for firm but yielding, not stuffed to bursting.

Organic cotton: gentle, natural, and best for heirloom makes

Organic cotton filling comes as loose fibre, carded batting, or sometimes in sheets. Certified GOTS cotton guarantees organic farming and fair processing, which matters if you are marketing a toy as eco-friendly. It is soft, hypoallergenic and reassuringly natural, and it composts at the end of a toy's long life.

What it is not is lofty. Cotton is dense and heavy, so it gives a lovely satisfying weight to dolls, flat shapes and firm little bears, but it settles over time and needs generous overfilling from the start. It also clumps when wet and dries slowly, often taking two days of airing, and a toy stored damp can develop mildew. Treat cotton-filled makes as spot-clean pieces for older children or decorative shelf companions, and expect to pay two or three times the price of polyester.

Wool: warmth, springiness, and a few honest caveats

Carded wool batting or washed fleece is the connoisseur's choice. The natural crimp gives it remarkable memory, so a wool-stuffed bear bounces back rather than flattening, and it breathes, regulates temperature and resists dust mites. Wool is also naturally flame-resistant, which is quietly useful in a nursery. Look for mulesing-free wool, and British fleece where you can find it.

The catch is care. Wool felts when it meets heat and agitation, so hand wash at 30°C or below, never wring, and never tumble dry. Some noses notice a faint lanolin scent at first, wool allergies are real, and moths adore it, so store finished pieces with cedar or lavender. At £20 or more per kilo it is the priciest option, and it needs teasing apart properly or it sits in uneven lumps.

Washability, safety and the rules worth knowing

Whatever you choose, the filling must be clean, hygienic and impossible to escape. Double-stitch or overlock seams, backstitch at stress points, and close the turning gap with a neat ladder stitch. Toys made for sale in the UK must meet the toy safety regulations, covering mechanical hazards, flammability and the migration of certain elements, and be correctly marked.

• Polyester: machine wash 40°C, tumble dry low with a towel to redistribute the filling.
• Cotton: spot clean or hand wash cool, air dry flat for at least 48 hours.
• Wool: hand wash 30°C, press gently in a towel, dry away from radiators.
• Never use rice, dried beans, lentils, sand or foam offcuts in washable toys, and avoid polystyrene beads for anything a child under three might reach.

Matching the filling to the make

• Newborn comforters and small keepsakes: organic cotton, lightly filled, spot-clean only.
• Toddler's everyday teddy: recycled cluster polyester, generously filled, machine washable.
• Heirloom doll or christening gift: wool batting for shape and longevity, with cotton wadding in the limbs.
• Pram toys and decorative cushions: wool or cotton, where washing is rare and texture matters most.
• Large floor cushions and reading buddies: recycled polyester, which copes with being squashed nightly.

Buy a small bag of each, stuff three matching test bears, and wash them. Within a fortnight you will know exactly which filling belongs in your sewing basket, and your future makes will feel, wear and age all the better for it.