A lot of this is my point. As for a child eating something they thought was food. Yep, had that happen with my daughters marshmallow soaps. The mom was driving opened up her "Cosmetic" sample box and handed the marshmallow soap back to her 3 yr old son to eat. He did and hurled up all over the back seat. She threatened to sue us, but the package was clearly labeled Soap do not eat. Actually it was labeled Soap on all sides of the label for just this reason. Fortunately we did not get sued.Before I started selling, I sat down with a lawyer to determine if spending the extra money to create a LLC would be preferable to a DBA.
I also contracted an accounting firm to do both my business taxes and our personal taxes and asked their advice as well.
They both gave me the same advice to go with a DBA for these reasons:
1) There was no real benefit to my creating a corporation since I didn't plan to establish lines of credit with vendors to purchase my supplies. In other words - I wouldn't be in the position of having outstanding debts if my business failed and the vendors sued for the debt.
2) If my LLC was sued for damages, I as the sole soapmaker/product creator would almost certainly be named personally in the lawsuit as well. Which means that our personal assets are now fair game.
And I just want to be clear on this since people have mentioned it - you don't have to have 'intent' to sell a dangerous/shady product to be sued. Anyone can sue you for the silliest of reasons, but they do have to prove that you were negligent or had 'intent' in order to win the lawsuit. Even if you win the lawsuit, you may be left with court/attorney fees unless you counter sue for these.
This is one scenario that the lawyer and I discussed:
A customer purchases a bar of soap/wax tart/etc. that smells good enough to eat and looks like food - then their child actually eats some of it. They take their child to the ER and then sue you for the bill and whatever else they can think up (mental distress/time off from work/etc) even though your product is clearly labeled as soap or whatever. Their main claim/basis for the lawsuit is that you didn't specifically say that this item was non-edible.
Of course this is completely outrageous and they would most likely never win such a case, but as the lawyer said: "As a LLC, you would have to defend both your corporation for allowing the product to be sold, and yourself personally as the maker of product in question."
And of course we have business insurance for nonsense like this, but the lawyer's advice was that if you ever get hit with frivolous lawsuit as a small business owner; file a countersuit to pay for your damages rather than file a claim with your insurance.
Many of the pointers that Cerelife mentions was my point that a corporation does not protect from everything. We have had a C- corp and a S-Corp and I can say I will Never have another Corporation. The S-Corp did not protect us from everything especially a credit card my partners ran up since it was personally guaranteed. In the ending my credit is trashed. The C-Corp did not protect our partner form mortgaging everything he had, including loans on retirement funds just to get rid of us... So he was not greatly protected