Materials, construction and quality control

We stock long-pile, short-pile, curly and velboa plush, plus minky, ripstop and spandex for stretch panels. Pile length is chosen for viewing distance: long pile reads soft from ten metres but muddy up close, short pile holds detail for meet-and-greets. All plush is colour-matched to Pantone or to a physical swatch, and we record the dye lot so a reorder matches.

• Long-pile plush (25-40 mm) for bears, lambs and soft animal characters
• Short-pile and velboa (3-9 mm) for faces, detailed characters and close contact
• Ripstop nylon and coated polyester for inflatable body shells
• Four-way stretch spandex at shoulders, hips and knees for range of motion
• UV-stable dyes on request for costumes used outdoors daily

Heads are built from layered EVA and high-density polyurethane foam, hand-carved rather than moulded, which is why a one-off costs the same per unit as the tenth. Density is chosen by function: dense foam at the crown where the harness loads it, softer foam where the shape needs to be forgiving against a child's face.

• Layered EVA and PU foam, hand-carved to the approved sculpt
• Internal cage or harness that transfers head weight to the shoulders and hips
• Reinforced crown where the harness attaches — the first failure point on cheap builds
• Shape-retaining foam that recovers after compression in a travel case
• Wire armatures inside ears, tails and antennae so poses hold

Overheating is the single most common reason a mascot programme stops. Every head we build ships with at least two 12 V fans and a rechargeable pack; large builds get three. Vision panels are mesh with an anti-fog treatment, and the lining is a moisture-wicking mesh that can be removed and washed.

• Two or three 12 V fans, positioned to move air across the face and out at the crown
• Rechargeable battery pack, 6-10 hours per charge, spare pack supplied
• Anti-fog mesh vision panels sized to the performer's eye height
• Removable, machine-washable moisture-wicking lining
• Optional cooling vest with reusable gel inserts for hot climates

Stress seams — crotch, underarm, shoulder, knee — are double-stitched and bar-tacked. Zippers are branded units in a size that can be replaced by any local tailor, not a proprietary part you have to order from us. Gloves and feet covers are treated as consumables and supplied with a spare set.

• Double-stitched and bar-tacked stress seams at the four common failure points
• Standard-gauge replaceable zippers with a storm flap over the back closure
• Spare gloves, feet covers and a small repair kit with every costume
• Reinforced abrasion panels at knees, elbows and seat for sports builds
• Hook-and-loop closures backed with stitching, never glue alone

We can build to EN71-2 and EN71-3 material requirements, supply flame-retardant fabric to BS 5852 or NFPA 701 where your venue demands it, and provide material declarations for your compliance file. Tell us at quotation stage — retrofitting compliance to a finished costume is not possible.

• EN71-2 flammability and EN71-3 migration-of-elements compliant materials on request
• Flame-retardant fabric options for venues with fire-safety requirements
• Nickel-free and low-migration hardware for costumes used around children
• Material declarations and supplier certificates supplied per production run
• No small detachable parts on builds intended for close child contact

Every costume is worn and walked by a member of our team before packing — that walk test is the video we send you. We check against a written 18-point checklist covering vision, balance, seams, hardware, fan function, colour match and finish, and we photograph the costume as packed so any transit damage is provable.

• 18-point written checklist signed off per costume, not per batch
• Walk test filmed and sent to you before the costume is packed
• Colour compared against the approved swatch under standard lighting
• Fan runtime verified on a full charge before shipping
• As-packed photographs supplied for your records and any insurance claim