The process of creating this plush started with TrevyMetal sharing an illustration of his Green Meanie character. He also shared some great reference of similar existing products that he liked, that helped me visualize what he would like to see with his character turned into plush.
From his drawing, I made my own sketch of the front and back. Making my own drawing helps me think of how the flat drawing will be built into a 3D shape made of multiple pattern pieces. The Green Meanie has some interesting facial features that needed to be shaped out like the folds in its nose bridge, the pushed out eyelids, the flared mustache and the muzzle shape. I made various versions out of muslin, going back and forth tweaking paper pattern pieces and sewing up sample variations until it looked good. Then I made a full plush fabric version for TrevyMetal and sent it to him in person. Once he could feel it, he had a couple more adjustments. I included those in the next sample and then the Green Meanie plush was officially created.
I made a limited edition run of just 25 pieces with a custom embroidered logo, which sold out quickly as there are some big TrevyMetal fans out there.