Evenflo Recalls Over 300,000 Child Seats Due to Choking Hazard

Evenflo Company, Inc. is voluntarily recalling more than 324,000 of its Revolve360 Slim child car seats, as reported by the U.S. Department of Transportation’s National Highway Traffic Safety Administration (NHTSA). The recall addresses a potential choking hazard posed by pieces of the foam headrest that children may be able to detach and ingest.

The defect affects numerous models of the Revolve360 Slim child car seat manufactured between December 2022 and November 2024, encompassing a wide range of model numbers and specific color variations. Evenflo has received reports of children accessing the foam headrest material, with some instances involving ingestion of the foam pieces and others where the pieces were placed in the child’s nose or mouth. The primary concern is that detaching and ingesting these foam pieces could create a choking hazard for young children.

The issue stems from the design of the headrest, which is located beneath the soft goods cover and is accessible to children. While a tape seal is intended to prevent children from reaching the foam, the current application has proven insufficient for some children to access and pull off pieces of the foam. Evenflo has documented 11 reports specifically detailing children picking off and ingesting foam from the headrest of these affected seats. Additionally, there are twelve other reports of children accessing the foam without ingestion.

Evenflo has initiated a remedy program to address this safety concern. Consumers who own an affected Revolve360 Slim child car seat will be provided with a remedy kit that includes an additional tape seal. Once this seal is installed by the consumer according to the provided instructions, it will further secure the headrest foam and prevent access. Evenflo expects to begin notifying owners and providing these remedy kits between October 31, 2025, and November 11, 2025, with the exact date of availability to be determined. Subsequent models of the Revolve360 Slim have been redesigned with a different headrest to prevent this issue. While the recall encompasses the entirety of production for the identified models, newer versions of the seat in production may incorporate these design changes.

Consumers are advised that a warning sign of the issue may be apparent if a child is observed attempting to access the foam headrest. In the interim, parents and caregivers are urged to monitor their children closely when in the car seat. While the recall notice does not include a “Do Not Drive” advisory, the potential for a choking hazard necessitates prompt action. Evenflo has also established a reimbursement plan for caregivers who have already incurred costs due to the recall condition, by providing replacement products to those who reported the issue.

Article by Mel Anara, based upon information from the U.S. Department of Transportation’s National Highway Traffic Safety Administration.

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