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How Nugget approaches quality, safety, and testing

Nugget safety, materials & how it’s made

There’s nothing Nugget takes more seriously than keeping Nuggeteers safe.

As a company that makes products for children, we believe families deserve to know exactly what’s in their Nugget® products, as well as how our products are designed, tested, and assembled.

What is Nugget play furniture made from?

Foam

Nugget® play furniture uses open-cell polyurethane foam sourced from a North Carolina partner. It’s comfortable and malleable, yet sturdy enough to withstand countless jumps, builds, and obstacle courses.

All of our foam is also CertiPUR-US® certified, and it has passed rigorous standards for emissions, content, and durability.

Fabric

We currently offer five different fabrics (microsuede, double-brushed microsuede, corduroy, denim, and teddy) in a multitude of Nuggety colors.

They’re all GREENGUARD Gold certified, machine washable, and super durable for everyday play, but each fabric looks and feels different. We work with a North Carolina-based supplier to source our Cover Set fabrics from hubs in Vietnam, China, and El Salvador.

Liner Sets

Optional Liner Sets provide an extra layer of protection between the foam and Cover Set. They’re double-layered with a 100% polyurethane material for waterproofing and a 100% polyester gray top for durability and quality.

 Liner Sets are also GREENGUARD Gold certified and machine washable!

Certifications & testing

  • GREENGUARD Gold Certified

    All Nugget play furniture is GREENGUARD Gold certified. Gold has more stringent chemical-emissions limits than standard GREENGUARD certification.

  • CertiPUR-US® Certified Foam

    Nugget foam is CertiPUR-US® certified for emissions, content, performance, and durability.

  • Additional Third-Party Testing

    Nugget products also undergo independent testing by a CPSC-accredited laboratory for physical and mechanical safety and substances such as lead, phthalates, and heavy metals.

Does Nugget® use flame-retardant chemicals?

Nope. Here’s why: Flame retardant chemicals are added to all kinds of products to help slow the spread of a potential fire, but some of those chemicals can linger in the environment or your body for years. Some of them may even be harmful to your health. 

For those reasons, we’ve chosen not to use flame retardants in our products. That said, Nugget® products still meet California’s TB-117 requirements (meaning, they must resist ignition from a smoldering source, like a lit cigarette) without using any of those flame-retardant chemicals.

How Nugget play furniture comes together

From North Carolina foam to Cover Sets made by our trusted manufacturing partners, each piece takes a journey before it arrives at your door. Here’s a look at how our play furniture comes together.

1. Foam

Our foam is sourced from a partner in North Carolina, and we cut it in-house.

2. Cover Sets

Cover Sets are manufactured by trusted partners abroad before making their way to Nugget HQ.

3. Assembled in the U.S.

Production team members “dress” the foam into appropriate Cover Sets at our facility in Butner, North Carolina.

4. Quality control

Nugget®, Chunk®, and Smore™ pieces are checked by hand for defects.

5. Compression & packing

Finished play furniture is compressed, wrapped in plastic, and dropped into a Big Orange Box.

6. Final touches

Boxes are sealed and labeled, then loaded onto a delivery truck.

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How does Nugget approach quality control?

Quality control isn’t limited to the production process. We’re keeping an eye on materials and products every step of the way!

We perform quality control checks:

  • When we’re play-testing a new product 
  • When new material — foam and fabric — arrive at HQ
  • When foam is cut
  • When the product has been fully dressed
  • Before the product enters its packaging
  • After the product has been packaged

We also regularly service our many production machines, ensuring daily that they’re running smoothly and doing exactly what they’re supposed to.

  • Are Nugget products safe to play with?

    Yes! Have we mentioned that we really love safety? It’s Nugget’s highest priority. In fact, we have an entire Safe and Proper Use Manual available on our website for you! Basically, you should keep your builds low and stable, and follow the age and usage guidance for each product.

  • Are Nugget products easy to keep clean?

    Our products can handle whatever you throw at them — real or imaginary. But we know that messes still happen! Cover Sets & Liner Sets are machine washable, and your foam can be spot cleaned when needed. Find detailed instructions for caring for your play furniture on our Care page.

Frequently asked questions

What are Nugget® products made out of?

Our products are made from a harmony of custom-shaped open-cell polyurethane foam, cloaked in soft and durable fabric to achieve that elusive "just right" feel.

Check out Fabric Swatches if you’re not sure which color/fabric to choose!

Is the foam safe?

Our foam is CertiPUR-US® certified to exceed safety standards. It’s free of mercury, lead, and formaldehyde, and VOCs are minimal to protect indoor air quality.

How long does it take for that fresh foam smell (or "off-gassing") to fade?

Within a few hours! Most of this process has usually happened before a Nugget® product gets sent out, but sometimes, if the foam is particularly fresh, there might be a lingering scent (sometimes called off-gassing) when it's first opened. But we assure you this is a typical process and is totally safe! The smell should dissipate within a few hours at longest, and you’ll be on your way to fort-building fun!

In the meantime, we can assure you that all of our products are GREENGUARD Gold certified, which means they’ve been rigorously screened and scientifically tested for more than 15,000 VOCs, and they don’t emit any harmful chemicals. You can rest easy and play all day, knowing Nugget® products are safe for children, families, and the environment.

Are there any rules for playing with Nugget® products?

We know, we know... no one likes rules, but safety is at the top of our priority list — it’s why all our products go through extensive testing, long before landing on your doorstep. So, consider this the Playtime Playbook:

Adventure zone: The Nugget® is for kids (and kids at heart) who are 1+ years old, Smore™ is for ages 2+ years old, and Chunk® is for ages 3+ years old — our products are for exploration and adventure and are not for sleeping!

Keep it light: There should never be heavy items on top of Nugget products when someone is inside or underneath.

Stay open: Push it, move it, or roll it from the living room to the playroom to the kids' room — just keep play in open spaces, not on or around stairs or windows, and use caution on hard surfaces.

Adult supervision required. For more on proper use, please visit our Safe and Proper Use Manual.

Can children sleep on Nugget play furniture?

Nugget products are designed and tested for supervised play, not sleeping. Because they have not been evaluated or certified for use as sleep products, Nugget products should not be used for that purpose.

We’re here to help!

  • Questions about materials, safety, or how we make our products? Our Customer Experience team is available during business hours, Monday-Friday 9-5pm ET.

    Contact Us

  • Looking for help with ordering, shipping, warranty, or something else? Find quick answers in our most popular FAQs.

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