Safe by Design: Sizes, Edges & Hardware for Wooden Toys

The dimensions that decide whether a wooden toy is safe, and the ones that only look like they do. Written for a home shop with a drill, a jigsaw and a sander, and built around numbers you can work to rather than reassurances.

What is inside

• The 16 CFR 1501.4 small-parts cylinder, drawn 1:1 so you can print a true-size profile
• Age grading: what CPSC actually looks at, and why a printed label is not a decision
• Designing so a toy does not break into a small part under use and abuse testing
• Edge radii, sharp-point rules, and why maple is preferred over oak for reasons other than hardness
• Cord, axle and fastener limits, including the 220 mm pull-toy rule
• Lead limits for coatings and substrate, and the untreated-wood testing exemption
• What the paperwork looks like if you sell the toys rather than the plans
• A worked pull-along cart, dimensioned against the rules
• A fifteen-point checklist and a one-page table of every figure with its source

Format

• 12 pages, A4, PDF
• Delivered as an instant download after purchase
• Print at 100% with scaling off — several drawings are reproduced at true size
• No physical item is shipped

Please note

This is a design guide, not legal advice, and it does not substitute for testing. Regulatory figures are cited to their source so you can verify them against the current text.