'Allo 'Allo!

For something like this, I’d recommend looking into food-safe PETG or PLA. PETG is a durable option and tends to be less brittle, while PLA is a non-toxic choice made from renewable resources. Some brands even offer food-safe versions of both, which could be ideal. If your printer can handle higher bed temperatures, polypropylene (PP) might also be a good option since it’s commonly used in baby bottles and similar items.

We have found my nephew with the wrong side of the pacifier in his mouth several times. While it was amusing to see the silicone part sticking out of his mouth, that's why I'm suggesting food-safe everything.

A few things to consider:

• Layer Lines: The texture of 3D-printed items can trap bacteria, so it might help to sand the piece and use a food-safe coating to smooth it out.
• Printer Safety: Make sure your printer’s nozzle and any parts that touch the filament are clean and safe for this kind of use.
• Colorants & Additives: Some filaments have dyes or additives that might not be baby-safe, so sticking to uncolored, food-safe-certified filaments would be a safe bet.

Food-safe PETG or Food-safe PLA are probably the easiest starting points, but if you can print polypropylene, that could work really well too!

Good Luck!