Production Process

It is not just the attention to detail which gives our character mascots heart, it’s that twinkle in the eye and saucy grin which turn a Sugar’s mascot into a crowd-pleasing, huggable mascot costume.

Sugar’s Mascot Costumes has been making exceptional mascots for over 30 years. We work very closely with our clients through the design process, and our mascots are created entirely by hand in our studio. Each one is a one-of-a-kind work of art.

We understand the importance of approaching a mascot design with a completely fresh outlook… your outlook!   At Sugar’s Mascot Costumes we always consider durability, longevity, safety, comfort and manageability when producing our mascots!

Before we even make the first cut, we will ask you a lot of questions to make sure we get it right. We will consult with you regarding colours and construction details of your unique character. We will also require certain details from you at this point, such as a high resolution logo and the size of your performer(s).

Behind the scenes, we have many production meetings to discuss key considerations for your character, and methods of construction. Amongst these considerations, care is taken to provide maximum vision and ventilation using innovative techniques, while maintaining the overall design.

By both listening to your needs and wishes, and consulting with our team of experts, we work to create a character that looks great, feels great, and works well in its environment. From initial questions to final product, our production process generally takes 10 to 14 weeks. Need your mascot in a hurry? Give us a call today, we may be able to make arrangements for rush orders!


First Stage of Production Approval

Inquire about custom mascot costumes

Shortly after your mascot moves into the production schedule, you will receive a technical sketch. This provides you with measurements of your character’s proportions to confirm we are building a character that is the right size for you. This drawing will be used as a size reference when sculpting your character, so we feel that it’s important to include you in this part of the design process. It is sometimes helpful at this point for you to take out a tape measure and stretch it out to gain a better understanding of the size your character will become. Keep in mind that measurements on the technical sketch indicate the outside measurements, not that of the performer. After all, mascots can have a lot of padding inside. A mascot with a 47” waist will not necessarily be able to accommodate a performer with a 47” waist.


Approval of Colours and Materials

Materials for custom mascot costumes

Based upon our consultations with you, we source and purchase materials for your character. We send you photos of these materials for your approval, before moving into official production. If you provided us with specific colours (Pantone numbers), we will be able to show these colours side by side with potential materials. If your deadline allows some additional time, we can even mail fabric samples to you for your review.


Crafting Your Mascot

Crafting custom mascot costumes

At this point in the process, your mascot is crafted by our team of talented and experienced artisans. Custom patterns are drafted, materials and various foams are cut, sewn and sculpted by hand to create the character that will become your mascot!

As the various departments work on your mascot character, your account manager will continue to send you updates and “behind the scenes” photos to keep you in the loop. Sometimes mascots look strange when they’re in pieces, but it is neat to have a peek behind the curtain! Your feedback is always welcomed, and even encouraged.


Completion and Final Approval

Final approval for custom mascot costumes

Once your mascot is complete, we will have someone model your character for you and your account manager will send you photos from every angle, along with a brief video clip. Seeing your mascot come to life for the first time is very exciting! Typically we will be able to ship your character shortly after you have sent your approval of their final photos. Because you have been involved at every stage, there should be no surprises. However, if you have any questions or concerns at all, please let us know!




Upon approval and receipt of final payment, we will ship your completed character to you. Your account manager will provide you with a tracking number, and our shipping department will track your mascot until it arrives on your doorstep. We will make sure that you’ve received your mascot in good order, and we will be available for any questions after your first try-on. But this won’t be the last that you hear from us! We really want you to be happy, and we value your feedback; that’s why we’re always just a phone call away!


Outstanding Support

Support for custom mascot costumes

We stand by our work once your mascot is completed and in your possession! Our mascots come with a warranty, but in addition, they come with a team that has been making mascots since 1985. We pride ourselves on our outstanding support, and are sure to provide every client with a detailed care and cleaning manual, with helpful hints on setting up your own mascot program. You can also join our mailing list where we’ll continue to inspire you with detailed articles on mascotting, as well as advice, trivia, and performer hints! Furthermore, we maintain a full service cleaning and maintenance department to ensure that you have as much support as you need throughout your mascot’s lifetime.

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