Start with popped popcorn, not kernels
The six-cup quantity is ready-popped popcorn. Pick through it before adding chocolate and discard unpopped kernels while they are easy to see. Have the large lined tray and measured decorations ready before melting; once the chocolate coats the popcorn, the next job is spreading it and adding the pieces while the coating is still soft.
Toss gently so the popcorn keeps its shape, then use a single layer rather than a deep mound. Let the chocolate set before breaking the mixture into clusters. Choose decorations appropriate for those eating, and keep popcorn and hard small candies away from young children who cannot manage them safely. Store the finished clusters protected from moisture rather than leaving them in an open serving bowl for later.
Choosing treats for children
CDC guidance on choking hazards and development-appropriate preparation



