Baby Product Printing for Bebebow: The Sensory Arch

We’re delighted to have produced Bebebow’s first product, the Baby Sensory Arch. One of a new generation of baby sensory toys for newborns developed around early years developmental principles. Designed to encourage natural head turning from day one, the arch provides stimulation whilst helping babies build shoulder and neck strength through play. It is suitable from birth, was developed with early years educators, and is UKCA compliant.

Following two years of research and product development, Bebebow approached Imago with the structural concept and material direction already established, ready to bring the product into commercial production. That involved working through the practical side of the print and finishing process, making sure the materials and different production stages worked together to produce the finished arch.

Turning the concept into a finished product

The sensory arch is made from two concertina pieces which slot together to form the arch. They need to fold flat when they’re packed away, but once they’re assembled they have to hold their shape and fit together properly.

That meant the print, materials and finishing all had to work together. The folds needed to be clean, the interlocking areas needed to be accurately cut, and the two pieces needed to remain consistent throughout production.

The Construction Challenge

Each of the two concertina pieces is a three-layer laminated construction, with a lightweight internal core. Achieving the right balance between weight, structure and precision was one of the central technical challenges of the project.

The relatively large format of each piece also meant that production required specialist machinery capable of handling the size while maintaining a high degree of accuracy. The folds, die-cut areas and overall alignment all needed to be produced within tight tolerances so that the two pieces fitted together correctly and the arch held its intended shape.

Print registration also needed to remain highly precise across the full format to preserve the visual alignment and premium finish of the product.

Foam lamination

The layers were laminated together with consistent bonding across the finished format.

Scoring and die-cutting

The laminated material was scored and die-cut to create the folds and interlocking areas needed for assembly.

Building the structure

Each piece needed to be produced accurately so the finished arch could be assembled as intended.

Safety Requirements

Bebebow is designed for use from birth, so the materials and production processes needed to be considered alongside the product’s UKCA requirements.

The finished product is UKCA compliant and suitable from birth.

The Packaging

The folded arch pieces and instruction sheet needed to fit into a compact tuck-in box, slim enough to go through a standard letterbox.

Imago produced the printed packaging, including the die-cutting, scoring, forming and gluing.

Project Specifications

Sensory Arch
2 × concertina arches

Construction
Printed board with a lightweight internal spacer
Laminated construction

Finishing:
Scoring and die-cutting
Protective matt finish

Packaging:
Letterbox-friendly tuck-in box
Printed and matt finished

Safety:
UKCA compliant
Suitable from birth

Board
FSC™ certified board throughout

Why Choose Imago Group for Baby Product Printing?

Imago Group works with publishers and brands across a wide range of product formats, from collector edition hardbacks to consumer products like the Bebebow arch. What connects them is the need for a production partner who understands that the specification is not just a list of materials: it’s a set of promises to the end user.

For Bebebow, those promises were about safety, function and delight: a product that works first time, every time, and is designed for babies from birth and manufactured to meet the required safety standards.

We delivered that. And we’d love to help you deliver yours.