combines the functionality of a plastic container with the soft, fuzzy texture of plush fabric (like stuffed toys). This hybrid design is popular in cosmetics, baby products, and promotional packaging for its unique tactile appeal.
Here’s how it’s made and key considerations:
一、Design & Structure
- Inner Bottle: Standard plastic (PET, PP, or HDPE) for holding liquids.
- Outer Layer: Soft plush material (polyester fleece, velour, or faux fur) wrapped or molded around the bottle.
- Common Shapes: Cylindrical (easy to wrap) or custom molds (e.g., animal shapes for kids).
二、 Production Methods
Method 1: Fabric Wrapping (Most Common)
- Steps:
1. Bottle Production**: Blow-mold or inject the inner plastic bottle.
2. Fabric Cutting**: Laser-cut plush fabric to match bottle dimensions (+ seam allowance).
3. Adhesive Bonding:
- Use eco-friendly glue (water-based PU) or heat-activated adhesive films to attach fabric.
- For seamless finishes, sew the fabric into a sleeve and slide it over the bottle.
4. Embellishments: Add embroidery, patches, or silicone grips for branding.
- Pros: Low cost, customizable, soft texture.
- Cons: Not washable; adhesive may degrade with moisture.
Method 2: Overmolding (Advanced)
- Steps:
1. Injection-Mold the Bottle: Create the inner plastic core.
2. Insert Plush Layer: Place a pre-cut fabric or foam sheet into the mold.
3. Second Shot Molding: Inject a thin plastic layer (e.g., TPE) to bond the fabric to the bottle.
- Pros: Durable, waterproof (for TPE-coated fabrics).
- Cons: Higher tooling costs; limited to simple shapes.
Method 3: Slip-On Covers (Modular Design)
- Steps:
1. Produce a standard plastic bottle.
2. Design a removable plush cover (e.g., with elastic bands or zippers).
- Pros: Washable/replaceable covers; great for seasonal designs.
- Cons: Less premium feel; may slip off.
三、 Material Choices
Component | Options | Considerations |
Inner Bottle | PET, PP, HDPE | PET for clarity; PP for chemical resistance. |
Plush Fabric | Polyester fleece, faux fur, velour | Hypoallergenic for baby products. |
Adhesive | Water-based PU, EVA hot melt | FDA-compliant for food/beauty contact. |
Reinforcements | Silicone grips, stitching | Prevents fabric peeling |
四、Applications
- Cosmetics: Luxury perfume bottles (e.g., Gucci’s velvet-touch bottles).
- Baby Products: Plush-covered baby bottles or training cups.
- Promotional Items: Themed drink bottles (e.g., Halloween plush tumblers).
- Home Care: Soft-touch detergent bottles for premium branding.
五、 Key Challenges & Solutions
- Challenge 1: Fabric Durability
→ Use anti-pilling fleece or coat fabrics with thin TPU for abrasion resistance.
- Challenge 2: Water Resistance
→ Overmold with TPE or use removable covers for washing.
- Challenge 3: Cost Control
→ Opt for glue-bonding over molding for small batches.
六、Sustainability Options
- Recyclable Designs: Use mono-material (e.g., 100% PET bottle + PET fleece).
- Bio-Based Fabrics: Bamboo fiber or recycled polyester plush.
- Disassembly: Design for easy separation of plastic and fabric for recycling.
七、Example Products
- L’Occitane Limited-edition plush-wrapped hand cream bottles.
- Skip Hop** Plush-covered baby water bottles.
- Starbucks** Holiday-themed plush travel mugs.
If you need details on a specific method (e.g., adhesive formulas or mold design), let me know!
