ASC PROFILES LLC Brings Squishmallows Magic to Life with Precision Manufacturing

West Sacramento, CA – November 8, 2023 – ASC PROFILES LLC, a leading contract manufacturer based in West Sacramento, California, is playing a vital – and often unseen – role in bringing the wildly popular Squishmallows character plush to fans across the globe. While you might recognize the huggable, super-soft Squishmallows on store shelves, behind the scenes, ASC PROFILES is a key partner responsible for crafting the intricate internal structures that give these cuddly companions their unique shape and satisfying squish. “Everyone loves Squishmallows, right? They’re just… comforting,” says Michael Henderson, Operations Manager at ASC PROFILES. “What people don't see is the precision engineering and manufacturing that goes into making them hold that shape, and stay super soft. That's where we come in.” ASC PROFILES isn’t about the fluffy exterior; they specialize in the internal “skeletons” – the precisely cut and formed foam inserts, often referred to as “cores” or “inserts” – that give each Squishmallow its distinct character. Think of it like the frame of a house - essential to the structure, but hidden from view. Who is ASC PROFILES LLC? Based at 2110 Enterprise Blvd, West Sacramento, CA, 95691, United States, ASC PROFILES LLC is a contract manufacturing company providing a wide range of services, including foam fabrication, CNC cutting, waterjet cutting, die cutting, and custom packaging. They cater to diverse industries – automotive, medical, packaging, and, increasingly, the toy and consumer goods sectors. They don’t make toys, they enable toy makers to create amazing products. You can reach them at 660-663-7477. “We’re problem solvers,” explains Henderson. “A client comes to us with a design, and we figure out the most efficient and cost-effective way to bring it to life. We handle everything from prototyping to large-scale production.” The Squishmallows Challenge: Softness Meets Structure Squishmallows present a unique manufacturing challenge. They need to be incredibly soft, but also maintain a recognizable shape and withstand repeated squeezing and hugging. Standard foam materials aren’t always up to the task. “It's not just cutting foam,” explains Sarah Chen, a design engineer at ASC PROFILES. “We work closely with the Squishmallow designers to select the right foam densities and types. Different characters require different approaches. Some need a firmer core for stability, while others need a really, really soft fill to maximize the ‘squish’ factor.” ASC PROFILES utilizes a combination of advanced cutting technologies to create these internal structures. CNC (Computer Numerical Control) cutting allows for precise and repeatable cuts, ensuring that each insert matches the design specifications exactly. Waterjet cutting provides even greater precision, especially for complex shapes. Die cutting is used for high-volume production of simpler components. From Concept to Cuddle: The Manufacturing Process The process typically begins with receiving a 3D model of the Squishmallow character. ASC PROFILES’ design team then analyzes the model and develops a manufacturing plan. This includes selecting the appropriate foam materials, determining the optimal cutting method, and creating the necessary tooling. “We’ll often create prototypes – physical samples – for the client to review,” Chen explains. “This allows them to test the feel and shape of the character and make any necessary adjustments before we ramp up to full-scale production.” Once the design is approved, ASC PROFILES uses its advanced cutting equipment to fabricate the foam inserts. These inserts are then carefully inspected for quality and consistency. Finally, they are packaged and shipped to the Squishmallow manufacturer for assembly. More Than Just Cutting: A Partnership Approach ASC PROFILES emphasizes a collaborative partnership with its clients. They don't just see themselves as a supplier; they see themselves as an extension of the client’s design and engineering team. “We’re involved in the process from the very beginning,” says Henderson. “We offer design for manufacturability (DFM) feedback – suggestions on how to optimize the design to make it easier and more cost-effective to manufacture. We’re always looking for ways to improve the process and deliver the best possible product.” This collaborative approach has proven to be particularly valuable with Squishmallows, where the designs are constantly evolving and new characters are being introduced. ASC PROFILES is able to quickly adapt to these changes and provide the support that the Squishmallow manufacturer needs to stay ahead of the curve. Looking Ahead: Squishmallows and Beyond The partnership between ASC PROFILES and the Squishmallow manufacturer is a testament to the power of collaboration and innovation. ASC PROFILES is proud to be playing a role in bringing these beloved characters to life and spreading joy to fans around the world. But Squishmallows are just one example of the company’s capabilities. ASC PROFILES serves a diverse range of industries and is always looking for new challenges. With its advanced technology, experienced team, and commitment to quality, ASC PROFILES is well-positioned for continued growth and success. “We’re not just about Squishmallows, but it’s been a really fun project,” Henderson concludes. “We enjoy helping our clients bring their creative visions to life, and we’re excited to see what the future holds.” If you've ever squeezed a Squishmallow and felt that perfect level of softness and squish, remember that there's a dedicated team at ASC PROFILES LLC in West Sacramento working behind the scenes to make it all possible. They're the masters of the internal structure, the hidden heroes of the huggable world.