juiseshop,
You may want to see if you can get help from your local SCORE mentor or the regional SBA office in obtaining professional legal advice about making and selling specific products due to the complexities of the CPSC, CPSIA, and other federal offices, like the FTC, that may have regulations or laws concerning a certain type of product.
Basically, under the CPSIA, the lead and phthalate testing for non-exempt materials falls into 3 categories:
1* Testing of the completed finished product - this testing is where you take random samples of each batch of an item that you make to send to a CPSC approved lab to be tested.
2* Component testing - where you take random samples of each batch of non-exempt supplies you plan on using on various different products and have them tested at a CPSC approved lab prior to assembling them into your products.
3* "Already tested" or GCC available - refers to supplies that few component manufacturers that have tested, using the CPSIA approved tests even though they may not be required to, and are willing to pass along the test reports or a GCC, in the format needed to satisfiy the CPSC, for their products that will go into your finished items.
There are pros and cons to each type of testing route you can choose from.
Option 1 - requires each time you open a new package of a supply to retest the entire finished product as a new batch. On the other hand this type of teting gives the lab a chance to tell you if the are additional tests that should to be done; like choking hazards, breakability, or construction value testing; based on what the finished product is.
Options 2 and 3 require a lot more paperwork on your part in trying the multiple test reports back to a finished product, but offer flexibility on producing OOAK and custom order products.
As you said for the clothing you want to design you plan on using blanks that are technically really a ready to use "as is" product, so the trick is to get the test results from the blank's manufacturer showing that it has passed or is exempt from any CPSIA testing. Even if all you where planning on was to sell the blanks a supply to other crafters as a "reseller" you would still need to have a GCC or COC from the manufacturer on file at your business office. The problem is if your buying the blanks at a retail level the store nor the manufacturer are required to pass the testing information on, you may have to prove you have a business to business relationship with the retailer before they are willing to send you additional information. So if you're unable to get the test reports, COC, or GCC from the manufacturer or retailer you may still need to choose which testing route you would like to take. Remember there are also requirements on fabric based items that need to follow the laws and regulations that are under the prevue of the FTC.
Now if your taking otherwise exempt materials like untreated, uncoated wood or a 100% cotton tee-shirt and add non-exempt pieces or finishes to it, component testing or testing done by the non-exempt supply manufacturer will save you money. Many of the labs base their pricing on how many different base material components are used to make a finial product and to cover their behinds want proof of exemption or reports of tests already done if you want only certain parts of the product tested for lead & phthalate compliancy. Otherwise they take the finished product apart and test all the seperate pieces individually since a button will disolve in the acid at a different rate than the wood or glue will.
The CPSIA considers screen print inks to fall in the same category as paint and is subject to the even lower lead limit of 90PPM and additional testing for like 12 other "hazardous substances". A can or container that just states non-toxic without reporting exactly what tests were used or what the result in PPM were for each substance that required testing does you no good. Again you will need to get specific test results in the format that is allowed by the CPSIA, and you can choose which testing route you would like to follow.
I'm not too sure about the testing procedures that are required for small parts, choking, sharp edges, strangulation, durability, and breakability, but I do know that they vary based on what the final product is and the terget age group the product is aimed at. So the tests a toy car may have to go through will be completely different from the testing a plush animal is going to need which is again differernt from what an appliqued bib will go through. Again a test for a toy car that is being targeted to the age group of 3 to 6 will be different from a toy car targeted at children over 7. Some of the tests could include throwing a toy a specific distance at a specific force against a wall to sell if anything chips off or causes a sharp edge, or they could test for what happens if a child fall asleep while hugging or wearing the product, while another test might simulate a tug of war between the target age group and an older sibling to check for tearing or another test might include to see if saliva will weaken the glue causing seperation. This area is perhaps were professional legal help is most needed.