Need to replace the foam in your seats or cushions? We have a large selection of foam types and can make just about any shape you need!
(Scroll down for descriptions on the foam types)
Return Policy
Custom cushions cannot be accepted for return unless there is a product defect or a manufacturing error. Please see our Return Policy for more information. If you have questions concerning our return policy, please Contact Us before placing your order.
Manufacturing Tolerances
Custom-cut seats and cushions have dimensional tolerances according to the "Custom-Cut Cushions" section of our Dimensional Tolerances table. If your project requires a tighter tolerance, Contact Us for more information about machine cut custom items.
Largest Solid Sheet
The largest solid sheet available for couch foam, boat foam, mattresses, or any other custom shape is 76" x 82". Please be aware that when ordering pieces larger than this, the foam will be glued to another piece to meet the requested dimensions. There will be no additional gluing charges in this situation.
Largest Solid Thickness
The largest solid thickness available is 6". Please be aware that when ordering pieces at a greater thickness than that, it will be made from two matching pieces glued together to achieve the desired thickness. Up to 8" thickness, there are no additional gluing charges. For thicknesses greater than 8", an additional gluing charge will apply.
Poly Foam
A medium firmness foam suggested for occasional use. Poly foam can be used for cushion replacement and mattresses, as well as packaging and crafts. It has a typical life of 1 to 2 years.
(Poly foam has a 1.5 lb/ft3 density with a 36lb ILD)
Poly Foam
Poly Foam Datasheet
Super Soft Foam
A soft foam suggested for regular use. Super Soft Foam is suggested for the back of sofa cushions, mattress toppers and mattresses for individuals with bed sores. Super Soft Foam is NOT suggested for chair or seating cushions. Foam has a typical life of 5 years.
(Super Soft foam has a 1.2 lb/ft3 density with a 12lb ILD)
Super Soft Foam
Super Soft Foam Datasheet
HD36 Foam - Regular
Medium feel foam for regular use applications. HD36 Foam - R is suggested for seats, chairs, cushions, benches, and mattresses. It is not suggested for dining rooms seats 1" to 2". We would instead suggest using our firm Lux Foam. HD36 Regular Foam has a typical lifespan of 7 years.
(HD36-R foam is a 1.8 lb/ft3 density with a 35lb ILD)
HD36 Regular Foam
HD36-R Datasheet
HD36 Foam - High Quality
Medium feel foam for regular or heavy use applications. HD36 Foam - HQ is a high quality foam suggested for seats, chairs, cushions, benches, and mattresses. It is not suggested for dining rooms seats 1" to 2". We would instead suggest using our firm Lux Foam. HD36 High Quality foam has a typical lifespan of 16 years.
(HD36-HQ foam has a 2.8 lb/ft3 density with a 35lb ILD)
HD36 High Quality Foam
HD36-HQ Datasheet
Lux Foam - Regular
Firm to extremely firm foam depending on thickness. Thicknesses from 1" to 6" are considered firm, and thicknesses from 7" to 8" are considered extremely firm. However, 7" to 8" thickness is considered only firm for body weights over 200 pounds in seating applications. This foam can be used for regular use applications. Lux Foam - R is suggested for seats, chairs, cushions, benches, and mattresses. It is also suggested for dining room seats from 1" to 3" in thickness. This foam has a typical lifespan of 7 years.
(Lux-R foam has a 1.8 lb/ft3 density with a 50lb ILD)
Lux Regular Foam
LUX-R Datasheet
Lux Foam - High Quality
Firm to extremely firm foam depending on thickness. Thicknesses from 1" to 6" are considered firm, and thicknesses from 7" to 8" are considered extremely firm. However, 7" to 8" thickness is considered only firm for body weights over 200 pounds in seating applications. This foam can be used for regular or heavy use applications. Lux Foam - HQ is a high quality foam suggested for seats, chairs, cushions, benches, and mattresses. It is also suggested for dining room seats from 1" to 3" in thickness. This foam has a typical lifespan of 16 years.
(Lux-HQ foam has 2.8 lb/ft3 density with a 50lb ILD)
Lux High Quality Foam
LUX-HQ Datasheet
Fiberfill Wrap (Dacron)
Polyester fiberfill wrap is highly suggested for cushions. It adds extra comfort to the cushion while filling it out for a more rounded, aesthetically pleasing appearance. It also makes sliding the cushion into its fabric cover much easier. If this option is selected, the cushion will come with a 1” thick layer of fiberfill that wraps around the entire foam insert, not just the top and bottom seating surfaces. Fiberfill may also be purchased separately under the Accessories section of our website.
We apply fiberfill wrap using fine upholstery staples. The staples do not enter the foam insert and will not damage your cushion cover.
IMPORTANT: Do not reduce your cushion measurements to compensate for the addition of fiberfill wrap. Fitting a cushion into a cover that's slightly smaller than the insert’s dimensions is what allows it to completely fill out a cover without any sagging.
