Why Use Upholstery Foam Sheets for Replacement Sofa Cushions

The average lifespan of a sofa is eight (quick!) years. Many people underestimate the sheer wear and tear your sofa experiences, and often neglect the lost comfort of yester-years. Although yet, to reinvigorate the comfort of your couch, a simple replacement foam cushion fix can do the trick – and there is no need for it to be an expensive outlay!

Buying sheet upholstery foam online gives you access to quality material at near trade prices. Not only are you maximising the amount of foam you receive, but you can be exposed the satisfaction (or IKEA-effect) of saving money through DIY.

As foam is such is an easily fabricated material, buying upholstery foam as sheet material is the chosen method for upholsters.

To simply DIY convert a foam sheet into cut to size replacement sofa cushions:

1. Measure sofa cushion dimensions

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a. Remove worn-out foam from the cover; place cover on a flat surface and measure the greatest length, width and thickness from seam to seam. Whilst measuring, hold the cover taut without stretching the material
  • Measure across the edges of the seams; to avoid measuring across the centre of the cover that may be misshaped by previous foam or filler
  • If you have piped edges on cushions, then measure between the piping
  • This method applies to square, rectangular, L-shape and T-shape cushions
b. Note these measurements down, and add 25mm/1” to each dimension to help create a fuller cushion

2. Plot dimensions onto foam with marker or chalk; or create a paper template for your foam

a. Tip: Use outer edges of foam as an edge of your foam to reduce the number of cuts required
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3. Use a long knife, possibly bread or meat knife, to score through the foam at your dimensions. Cut through the foam in layers to create a clean and careful cut – allow the blade to work through the foam!

a. Be careful not to compress the foam when cutting, as this create uneven lines
Cut foam b. If you so wish, elasticated stockinette can be added to your cut to size foam cushion to make the foam easier to install back into cushion cover

4. In no time at all, your replacement foam cushion is ready for use.


From a supplier’s perspective, sheet foam greatly slim-lines the production process helping to keep costs to a minimum, by converting the large raw material block via our huge foam splitter into usable 2m x 1m foam sheets at any thickness you require. Furthermore, due to its nature, foam can be packaged tightly without damage. (Click to see our foam splitter in action!)

Choose between:
  • Soft and medium upholstery grades: Standard grade upholstery foam suited to various domestic upholstery uses with a soft or medium firmness
  • Superior firm “blue”: High grade, firm upholstery foam with excellent durability and longevity suited to quality upholstery and sofa cushions, headboards, campervan seating and beds, and more
  • 6lb/8lb recon foam is often used in contract furniture for a thin, durable but cushioned seating. Often bonded via Tuskbond One Contact Spray Adhesive with a thin superior firm topper for a compact cushioning.
Foam is one of the UK’s largest domestic industries with long-standing manufacturers supplying specialist converters, like Foamrite.

Remember, after a car and house, furniture is the third most expensive item a person will buy. As you would service your car, service your sofa with replacement foam today

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