Custom Cut Foam

How to measure when ordering new foam replacement inserts

Things you will need:

  1. Pencil or Pen
  2. Measuring tape
  3. Paper to record sizes and to draw your cushion.
  4. Cushion(s)


  • Measure your cushion with cover on.
  • Measure from SEAM to SEAM pulling the material and the tape tightly, to the nearest ½ inch.
  • Round up not down. Thickness will be rounded up to the nearest whole size. i.e. 4.5 = 5, 1.5 = 2 and so on. 
  • Before you start measuring locate your cushion on the shapes below. This will help you identify how many measurements you will need.
  • Label your drawing and transfer your measurements to the web page with your desired shape.
  • A = Thickness of your cushion (measure the gusset seam to seam if it’s 4.5 round up to 5")
  • B = Depth in a seat, Height in a back (measure the corners for accurate sizes, seam to seam)
  • C = Width this is also known as your front measurement or side to side. (pull tightly, seam to seam round up to the to the nearest whole )
  • i.e.4.5 =5 1.5=2 and so on. 
  • If you do not have a cover yet measure the existing space to the nearest 1/4 and add ½ inch to your measurement. 
  • At this point you can unzip your cover and compare foam thickness. Keep in mind that you can always stuff thicker and soft foam into a smaller space, but you can not stuff thicker and firm foam into the same space. So measure with the cover on, after all you want the foam to fit the cover.
  • You can add a fibre wrap to your cushion without worrying about altering your sizes.
  • Fibre will give you a nicer look protect the fabric round corners and give some crowning.
  • Your cushion will look complete less wrinkling on the cover, also hide inconsistencies in sewing and stretching. 
  • If you need a replacement insert for an envelope-type* cushion cover, take the foam out the center and measure the FOAM. This is the only time you would order exact sizes.
  • Remember measure twice cut once.

Notes: *Envelope Cushion is a foam insert that is encased in down or feather.

Things to consider when picking out the right foam grade

Not all Foam is created equal and certain grades perform better than others. We compare the quality of the different Foam grades supplied by our Canadian suppliers and only select the best quality for our customers. Foams that feel good and we can feel good about selling. 

  • Foam grades have a four-part number the first two numbers represent the density or the weight of the foam the second set of numbers represents the firmness or the feel of the foam. As a rule of thumb, the higher the numbers the higher the density and the firmer the foam.
  • The foam will feel softer when you sit on it as opposed to when you lay on it. This is due to the weight being concentrated in a smaller area versus the distribution of weight over a larger surface. Choose firmness based on use, weight, and preference.
  • Keeping in mind that the thinner the foam the softer it will feel, in other words, a 2” firm will feel softer than a 4” firm.  A 2” firm will feel softer when sitting on it and firmer when lying on it. Choose firmness based on application.
  • Back cushions do not need to be very firm a medium or medium soft works well. 
  • It is supporting your back not your entire weight.