Evenflo Car Seats Allegedly Designed With Choking Hazard, Lawsuit Says

Case Overview: A new class action lawsuit claims Evenflo’s Revolve360 Slim and Gold Revolve360 Slim car seats pose a choking hazard because children can pull foam from the headrest. 

Consumers Affected: Parents and guardians in the U.S. who purchased affected Evenflo Revolve360 Slim or Gold Revolve360 Slim car seats made between December 2022 and December 2024.

Court: U.S. District Court for the District of Massachusetts

Baby gear giant Evenflo is selling car seats that pose a serious choking hazard to children while falsely marketing them as safe, a new lawsuit claims. The lawsuit centers on Evenflo’s Revolve360 Slim and Gold Revolve360 Slim models, popular car seats that retail for around $400. 

The complaint alleges that the seats were defectively designed, allowing infants to easily remove the headrest cover and access the foam inside, which can be torn off and put in their mouths. According to the filing, the company knew about the risk yet failed to warn consumers, all while charging a premium for its “safety-focused” products.

Evenflo voluntarily recalled roughly 324,000 car seats manufactured between December 2022 and December 2024 after receiving multiple reports of children pulling off the foam. But the recall, plaintiffs argue, doesn’t go far enough: Instead of offering refunds or replacements, 

Evenflo sent customers tape and instructions to seal the headrest, an inadequate fix, they say, that leaves children still at risk.

Parents Say Evenflo’s “Safety First” Marketing Hid Serious Defect

Debbie Barraza, a mother from Riverside County, California, filed the lawsuit after she purchased the Revolve360 Slim Canton seat online in January 2025 for about $295, believing it met the company’s advertised safety standards. Her model later appeared on the recall list. 

Barraza says she relied on Evenflo’s marketing, claims like “safety has never meant more”, when deciding to buy, and she wouldn’t have purchased the seat if she’d known about the defect.

The lawsuit alleges that Evenflo was aware, or should have been aware, of the headrest flaw well before the recall, citing reports as early as October 2023 of children mouthing pieces of foam. Eleven such cases were documented, according to the complaint, though no injuries were reported. 

Barraza argues that Evenflo’s recall remedy of mailing tape does nothing to make the product safe or restore the value of what consumers paid for.

Lawsuit Claims Headrest Foam Can Detach and Create Choking Risk

Evenflo is a major player in the competitive baby-products market, where safety is a key selling point. The lawsuit claims the company misled parents with assurances of superior safety and quality while concealing a design defect it knew could endanger children.

The foam-exposed headrest, the complaint states, renders the product “worthless” because it defeats the car seat’s fundamental purpose, protecting infants from harm. Consumers who stop using the seat must now buy a new one at their own expense, while those continuing to use it may unknowingly risk their child’s safety.

Evenflo Joins Growing List of Baby Product Makers Facing Safety Lawsuits

Evenflo isn’t alone in facing scrutiny over alleged defects in child safety gear. UPPAbaby is battling a class action lawsuit claiming its Mesa Max, Mesa V2, and Aria car seats cause babies to slump into unsafe “C-shaped” positions that can restrict breathing. 

Dorel Juvenile Group, maker of Safety 1st seats, is being sued over a recalled headrest design said to pose the same choking risk. Nuna, Fisher-Price, and Mattel have also been targeted by parents alleging their baby products, including swings and sound machines, can cause suffocation or electrical shock. 

And Bugaboo faces legal action over its Giraffe highchair, which allegedly allows its front legs to detach, sending children tumbling forward.

In her lawsuit, Barraza aims to represent all U.S. consumers who purchased the affected Evenflo car seats for household use. She’s suing for breach of warranty, unjust enrichment, fraudulent concealment, and violations of state business laws. 

The proposed class action seeks refunds, damages, and restitution, as well as punitive penalties and attorney’s fees.

Case Details

• Lawsuit: Barraza v. Evenflo Company, Inc.
• Case Number: 1:25-cv-12914-NMG
• Court: U.S. District Court for the District of Massachusetts 

Plaintiffs' Attorneys

• Christina Xenides, Mason A. Barney, and Leslie Pescia (Siri | Glimstad)
• Kevin Laukaitis, Daniel Tomascik, and Natalia Perez (Laukaitis Law LLC)

Have you used an Evenflo Revolve360 car seat or received a recall notice? Share your experience with the product and recall process in the comments below.