Evenflo Recalls 324,000 Revolve360 Slim Car Seats Over Internal Foam Choking Hazard

Evenflo has issued a major safety recall affecting over 324,000 Revolve360 Slim car seats across the U.S. and Canada after discovering that children can access and remove foam from inside the headrest—creating a serious choking hazard. While the seats’ crash safety performance remains unaffected, the ability of children to reach and pull out internal foam components poses a significant danger that has already resulted in multiple incidents.

What’s the Problem?

The affected seats, which have model numbers beginning with 3681, contain an internal foam pad behind the headrest that can become accessible through gaps or seams in the padding cover. Children may be able to pull out foam fragments and put them in their mouth or nose. There have been 11 documented cases where foam entered a child’s nose or mouth, plus 12 additional incidents where foam was accessed but not ingested.

While the foam itself is non-toxic, it still presents a real choking hazard. Evenflo has confirmed that the seats’ crash protection remains intact and the issue doesn’t affect structural safety.

Which Car Seats Are Affected?

Included in recall: Revolve360 Slim seats with model numbers starting with 3681

NOT affected: The original Revolve360, Revolve360 Extend, and Slim versions with model numbers beginning with CS2601 or 3682

To verify if your seat is affected, rotate it to its side and look for the white manufacturer label on the shell, which displays the model number and manufacturing date.

What Evenflo Is Offering

Owners of affected seats can request a free repair kit from Evenflo that includes a tape seal and instructions for blocking access to the foam area. These kits are expected to start shipping in early November. The seat may only be used if a child cannot physically reach the foam; if the foam is accessible or has been tampered with, the seat must be removed from service immediately. Seats do not need to be returned to retailers.

Action Steps for Parents

1. Locate the model label – Turn your seat over or to its side to find the white printed label on the shell
2. Check the model number – Verify if it begins with 3681
3. Test foam accessibility – Gently reach behind the headrest padding to see if foam can be touched or pulled
4. Stop use immediately if foam is accessible
5. Register for the repair kit – Visit Evenflo’s recall page to register your seat
6. Apply the repair carefully – Follow all instructions precisely when the kit arrives

Why This Recall Matters

This recall highlights a critical safety gap that extends beyond traditional crash testing. Many safety tests focus on impact forces and energy absorption, but fewer evaluate the long-term integrity of padding, seams, and internal material retention after years of use, handling, cleaning, and environmental stress.

This isn’t an isolated incident—earlier in 2025, Safety 1st’s Grow & Go Sprint seats faced a similar recall due to foam headrest access risks. The pattern suggests a systemic industry oversight: internal components must be secured against child manipulation throughout the product’s entire lifespan.

Key Takeaways

• Check your seat now if you own a Revolve360 Slim
• Stop using it immediately if foam is accessible to your child
• Register for the free repair kit and apply it carefully
• Monitor the repair over time to ensure it remains secure

This recall serves as an important reminder that child safety product design must go beyond passing crash tests—it requires resilient, tamper-resistant construction that holds up to years of real-world use by actual children.