Today I thought I would go back to basics a little as a few people have been asking how I stuff my softies so firmly.  I think that this all comes down to the equipment that you use so I thought I would share a few tips to get a firmly stuffed toy...

The first tip is repeating myself but maybe through the repeating it will capture some new readers.  The first rule of a strong and firm softie is to always use good quality polyester thread.  It is really important that you throw out the "patchwork" rules and take that cotton out of your machine whenever you start a softie.  Polyester thread is much stronger than cotton and will make your seams able to handle the strain of heavy stuffing.  The second tip on your stitches is to always set your machine to a small stitch of approx 1 - 1.5.  This again creates a stronger seam, makes the stitches less visible and creates a better end result. 

Another piece of equipment that is very important is your actual stuffing.  There is a big variance in the quality of polyester stuffings that are available.  Unfortunately one of the most available brands that is found in chain stores throughout Australia is very poor.  If you have been using this stuffing then you are probably getting lumps in your softies and getting a result that you are not happy with.  We buy our stuffing from a pillow factory as the quality is far superior and we need to buy in bulk but I have heard on the grape vine that Birch makes a good stuffing.  If any of you have any other brands you can recommend then please let me know so I can share it with everyone.  To help you in your search for the perfect stuffing, here is a little trick.  Grab a wad of the stuffing and roll it together into a ball in your hands.  If the stuffing remains in the ball you have made, with no spring back, then it is a poor stuffing and will create lumps in your work.  If the stuffing ball springs back then you know this is a great stuffing that will fill the space effectively without lumps.

The next piece of equipment that I wanted to share with you is our home made stuffing tool.  I have already shared the wooden skewer with you on another T&TT for all of your tiny pieces but this next tool is the all purpose super stuffing tool!! Go to your local craft store and buy a cheap round wooden paint brush like this.
 

The cost is under $2.00 so they certainly wont break the bank. This becomes a great double sided stuffing tool.  The smooth round end of the wooden brush is used at the perfect tool for turning your softie pieces and pushing all of the seams out smoothly.

The bristle end then becomes the perfect stuffing tool with a little modification. Grap some scissors (of course, don't be like me and use your sewing scissors so you have to buy a new pair!!!) and trim the paintbrush bristles to between a quarter and half inch.  No need to be neat.
 

Play with the remaining bristles for a while with your fingers and by rubbing them against a hard surface until you have messied them up really well.  

It should now look nice and shaggy like this
 

This shaggy end is now the perfect stuffing tool.  The reason that this tool is so helpful is that the shaggy bristles grip on to your stuffing.

This allows you to easily maneuver the stuffing into your toy and to keep shoving it in right to the ends until it is super firm.  When you place a piece of stuffing in with this tool the stuffing will stay with your tool so that you can get it right to the location that you want it to go.  

The last tip is to just keep on stuffing!!!  A lot of people are scared of stuffing too much and of breaking the seams, but if you have followed all of the tips above and your machine tension is correct then there should be little fear of breakage. Make sure that you support the area you are stuffing with one hand, while stuffing with the other and then keep shoving it in for as long as it will fit.  If you have stuffed some sections less that others, you should still be able to maneuver stuffing to those places with your trusty tool.

One question we often get is "Why do you attach eyes, nose, mouth etc after stuffing, and how do you do this so that knots aren't showing?" So here is a tutorial that is perhaps not easy to convey with pictures only or words only, but hopefully with the two combined it will make a lot of sense!
To answer the first part of this question, attaching applique pieces after stuffing a softie has two big benefits. The first is that a softie can be quite unpredictable and depending on fabric used, width/size of fabric pieces, firmness of stuffing etc, the end stuffie can be quite different in proportion than you initially thought.  With adding details after the toy is stuffed you have great control over getting the perfect placement and having a balanced toy.  The second reason is to avoid distortion or damage to your applique pieces.  One concern when doing your applique first is that the stitches could become damaged or pulled by your stuffing tool during the stuffing process. Another concern is that the fabric stretches (as it will do if you stuff firmly) and this may pull your stitches or even make holes in your backing fabric.  Of course this is not a hard and fast rule but it is the way we usually like to work.
For the second part of the question I will need to employ the help of some photos.  For this tutorial I am going to attach a nostril to this unfinished "Drake the dragon" by "sinking" the knots....

In preparation for this step, you will have attached the nostril to your softie with the use of fusible web and your iron.

Now thread your needle with the specified stands of embroidery floss (In this case I am using 2 stands of black floss), and tie a knot in the end as per usual.  I recommend that you tie a double knot in the case of 2 strands or as a rule, ensure that the knot is roughly the same width as your needle.

Enter the needle into your toy at a point a short distance away with the tip coming out at the exact place you want to start your stitching...

Pull the thread through and you will notice that the knot will catch at your point of entry, but of course we do not want to leave an ugly knot at the back of our toy.

Grab a hold of the thread, close to its exit point, and give it a quick short tug...

...this will cause the knot to pop through the weave of your fabric and "sink" inside the softie. You need to ensure that you do not tug too hard or violently or your thread will also come through the top side and you will need to start again.
....Now you can complete the sewing required on your softie. Of course this is not limited to just applique but is also the method to use for any stitching or attaching of limbs/ears etc etc....

Once you have completed your stitching (in this case, I have button-hole appliquéd the nostril in place) and are ready to take your last stitch, tie a knot close to the base of your thread. Again ensure that the knot is roughly the same width as your needle as shown.

Take your last stitch, threading the needle through to the same area that your entered before stitching (I recommend the back of your toy)..

Again your thread will snag when the knot reaches the fabric.  Tug the thread again to sink this finishing knot into the softie...

Cut the thread right at the fabric and this cut end will also sink into the toy..

...resulting in an appliquéd nostril with no visible threads or knots!!