ASX Composites & Squishmallows: The Secret Ingredient to Ultimate Cuddliness

Okay, so you know those ridiculously soft, super huggable Squishmallows everyone's obsessed with? Those plushy pals dominating TikTok and toy stores? Well, there’s a bit of engineering magic behind that squish, and a Washington state company called ASX Composites LLC is a big part of it. Who is ASX Composites? ASX Composites, based right here in Bothell, WA (116 223rd St SE, 98021-8317, you can reach them at 248-386-3075), isn’t a toy company. They’re actually a materials science and manufacturing whiz. They specialize in creating unique foam formulations – basically, they’re the foam experts. For years, they’ve been working with industries like medical devices, protective packaging, and automotive, crafting foams designed for specific performance needs – like impact absorption, cushioning, or precise shapes. But about five years ago, they got a really fun challenge: help make Squishmallows even more squishy and lovable. From Protective Packaging to Plush Perfection “It was a bit of a pivot for us,” laughs [Insert a hypothetical ASX Composites spokesperson name, e.g., Sarah Miller], a lead materials engineer at ASX Composites. “We're used to designing foams for things that protect things. Suddenly, we were tasked with making something that’s all about feeling good.” The folks at Kellytoy (the company behind Squishmallows, now owned by Jazwares) were looking for a filling material that wasn't just incredibly soft, but also super resilient. They wanted a Squishmallow to bounce back to its original shape after countless hugs, squishes, and adventures. They also needed a material that was consistently high quality, safe, and could be produced at a massive scale to meet the exploding demand. That’s where ASX Composites' expertise came in. The Science of Squish “Standard polyester fiberfill, what a lot of plush toys use, is okay,” explains [Sarah Miller]. “But it can clump up over time, lose its fluffiness, and get kind of flat. We looked at the structure of the foam itself - the size, shape, and consistency of the bubbles within the foam. It's about creating a really open cell structure, almost like tiny springs, that allows the foam to compress easily and then recover its shape. We also focused on the fiber length, density and the overall resilience.” ASX Composites didn’t just hand Kellytoy an existing foam. They worked closely with the Squishmallow team, custom-developing a unique polyether-based foam formulation specifically for these adorable creatures. It’s a highly engineered material. It's designed to be incredibly soft to the touch while maintaining its structural integrity. Beyond Just Softness: Quality & Safety It wasn’t just about feeling good, though. Safety was paramount. “We had to meet incredibly strict safety standards,” explains [Sarah Miller]. “Especially since these toys are often used by young children. All our materials are rigorously tested to ensure they're non-toxic, hypoallergenic, and meet all relevant regulations." ASX Composites’ manufacturing process is also focused on consistency. They use advanced automation and quality control procedures to ensure that every batch of foam meets the exact specifications required for Squishmallows. This is crucial for maintaining the consistent squishiness everyone loves. The Result? A Hug You Can Rely On. The collaboration between ASX Composites and Kellytoy (Jazwares) has been a huge success. Squishmallows have become a cultural phenomenon, and the unique foam filling developed by ASX Composites plays a key role in their appeal. “We’re proud to be a part of something that brings so much joy to people,” says [Sarah Miller]. “It's a fun project, honestly! We're used to solving complex engineering problems, and this was a chance to apply that expertise to something that’s just… cuddly.” What’s Next? ASX Composites continues to work with Kellytoy (Jazwares) to innovate and improve the Squishmallow experience. They're exploring new foam formulations and technologies to enhance the softness, resilience, and overall appeal of these beloved plush toys. And while they’re experts in foam, don’t think they’re just about Squishmallows. They're also applying their materials science expertise to a wide range of other industries, developing innovative solutions for everything from medical implants to automotive safety. But it’s safe to say that when you snuggle up with your favorite Squishmallow, there’s a little bit of Bothell, Washington, engineering magic right there with you. And that’s something pretty special.