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Before and after cushion with custom cut foam. Order Australian made foam online at Home Upholsterer

Foam Cut to Size - Custom Cushions Made in Australia

❓ Need help? View foam cutting guides, FAQs, and technical specs

1. Choose your shape & enter your dimensions:

a) 10 popular shapes to choose from :
Square cushion foam diagram Round cushion foam diagram L-shaped cushion foam diagram T-shaped cushion foam diagram Trapezium cushion foam diagram Back wedge cushion foam diagram Custom shape foam diagram
b) Enter your dimensions in millimeters (mm) here:
Enter foam dimensions in millimetres

Thickness:
mm
mm
mm
mm
mm
mm

2. Choose your Foam Grade & Quantity

a) Select your application(OPTIONAL)
b) How many cushions do you require?



3. Choose any optional extras for your cushion

(a) Polyester Wadding (Dacron) Wrap:
Square foam cushion - no dacron wrap Square foam cushion - top only dacron wrap Square foam cushion - L-wrap dacron Square foam cushion - top and bottom dacron wrap Square foam cushion - complete dacron wrap Circle foam cushion - no dacron wrap Circle foam cushion - top only dacron wrap Circle foam cushion - L-wrap dacron Circle foam cushion - top and bottom dacron wrap Circle foam cushion - complete dacron wrap L-shaped foam cushion - no dacron wrap L-shaped foam cushion - top only dacron wrap L-shaped foam cushion - L-wrap dacron L-shaped foam cushion - top and bottom dacron wrap L-shaped foam cushion - complete dacron wrap T-shaped foam cushion - no dacron wrap T-shaped foam cushion - top only dacron wrap T-shaped foam cushion - L-wrap dacron T-shaped foam cushion - top and bottom dacron wrap T-shaped foam cushion - complete dacron wrap Trapezium foam cushion - no dacron wrap Trapezium foam cushion - top only dacron wrap Trapezium foam cushion - L-wrap dacron Trapezium foam cushion - top and bottom dacron wrap Trapezium foam cushion - complete dacron wrap Back wedge foam cushion - no dacron wrap Back wedge foam cushion - top only dacron wrap Back wedge foam cushion - L-wrap dacron Back wedge foam cushion - top and bottom dacron wrap Back wedge foam cushion - complete dacron wrap

4. Review Specifications & Add to Cart

Shape:
Thickness:
Diameter:
mm
Width:
mm
Front Width(A):
mm
Depth(B):
mm
Back Width(C):
mm
Corner Depth(D):
mm
Bottom Thickness (C):
Top Thickness (D):
Foam Grade:
Foam Wrap:
Quantity:
Price per Cushion (Foam + Dacron):
Foam Total:
Dacron Wrap Total:
Grand Total:
Note (optional):

Added to cart

 Previous Projects

Cut to Size Foam FAQs - Everything You Need to Know

For everyday sofa cushions in residential applications, we generally recommend a premium heavy duty density upholstery foam such as grades N30-130, N31-190 or H35-200 depending on thickness and personal comfort. They offer long-lasting comfort and support without sagging, ideal for both brand new cushions and foam replacements.

Yes - we offer custom upholstery foam cut to size in most shapes, including square, rectangles, circles, T-shapes and more. Use our online foam calculator to order made-to-measure foam for cushions, mattresses, and other DIY upholstery projects.

Measure your cushion cover seam-to-seam and add 1-2 cm for a snug, full fit. For best results, check our foam FAQs for measuring tips or contact our Sydney customer service team for advice.

Yes, we supply high density foam cut to size for mattresses, mattress overlays, and bedding applications. All orders are shipped Australia-wide from our Sydney warehouse.

We recommend reticulated dry flow outdoor foam for external seating. It drains quickly, resists mould, and is ideal for patio, garden, or marine cushions that are directly exposed to the elements. If the foam is not likely to get wet and is kept undercover then regular indoor foam will be suitable and be more economically priced in comparison.

Foam density refers to the weight and durability of the foam, while firmness relates to how soft or hard you may prefer for a particular application. High density foam is more durable and long-lasting, but it can come in soft, medium, or firm options depending on your comfort preference.

High density seat foams like N31-190 or higher like commercial grade classifications foam tend to last the longest. They resist sagging and retain shape better over time, making them ideal for frequently used cushions, sofas, or mattresses.

We don't have pre-made samples as such but some customers may opt to order some small pieces of varying grades of foam to act as samples and help make an informed decision on which foam to pick for their particular project. The smallest size we can produce is 100x100mm in various thickness and grade selections.

Alternatively some customers may also wish to only purchase one finished foam cushion to use for short period of time in their application to test before ordering a larger amount of cushions.

Yes. We cut to any size for single, double, queen, king, and fully custom mattress dimensions. Memory foam overlays are also available for adding a comfort layer on top of an existing mattress. Thicknesses range from 12mm to 200mm and we ship Australia-wide from our Sydney warehouse — popular for caravans, boats, and replacement mattresses.

Yes — replacement couch cushions are one of our most common orders. Measure your existing cushion (or the cavity in your couch frame), select your foam grade, choose your shape, and we cut and ship. We also supply dacron wrap to go around the foam insert for that full, freshly upholstered look.

Upholstery Foam Cut to Size — Custom Cushions, Mattresses & Inserts

Looking for high-quality foam cut to your exact size and shape? At Home Upholsterer, we specialise in made-to-measure foam cushions, manufactured in Sydney using premium Australian-made foam.

Foam Types Available

Choose from our wide range of premium foam:

Browse All Foam

What We Can Make

We cut foam for any project:

Get a Quote

Fast Australia-Wide Delivery

Cut to order at our Sydney warehouse:

Contact Us

Ready to order? Use our interactive quote tool above to design your cushion, select the density and shape, and see pricing instantly.

Foam Grades at a Glance

Choose the right upholstery foam density for your project. Our high density foam and standard grades are Australian-made, available in thicknesses from 12mm to 200mm.

Grade Density (kg/m³) Firmness Hardness (ILD, N) Resilience (min) Best For
Indoor Standard Foam
SS15-60 15 Super Soft 60 ±10 35% Overlay foam, back cushions, light padding
N23-130 23 Soft/Medium 130 ±20 40% Back cushions, overlays, pillows
N30-130 30 Soft/Medium 130 ±20 40% Everyday sofa seats, dining chairs
N31-190 31 Medium/Firm 190 ±20 35% High-use seating, benches, window seats
N31-320 31 Very Firm 320 ±25 30% Firm seat cushions, high-traffic areas
H35-200 35 Medium/Firm 200 ±20 40% Heavy duty seats, boat berths
H42-500 42 Super Firm 500 ±60 20% Commercial heavy duty, industrial
N29-400 29 Very Firm 400 ±50 20% Packaging foam, acoustic panels
Commercial Fire Retardant (FR) Foam
HR36-100 36 Soft/Medium 100±15
 50% Commercial seating, hospitality (FR rated)
HR36-160 36 Medium

160±30

 50% Commercial seating, offices (FR rated)
HR40-230 40 Firm 230 ±20 45% Commercial seating, high-use (FR rated)
HR50-320 50 Super Firm 320 ±40 40% Heavy commercial, cinema seating (FR rated)
Outdoor Reticulated Foam
DF-SOFT 25 Soft/Medium 160 ±20 35% Outdoor back cushions, mattresses, marine
DF-FIRM

32

 Medium/Firm 270±20
 30%
 Outdoor seat cushions, patio furniture

Reading the specs: Density is nominal foam weight in kilograms per cubic metre (kg/m³). Hardness is the ILD (Indentation Load Deflection, also shown as IFD at 40%) in newtons, with the manufacturing tolerance after the ±. Resilience is the minimum rebound percentage. Higher density means longer life; higher hardness means a firmer feel. Figures marked TBC are being confirmed against the latest supplier data.

Pricing: From $0.99 AUD per piece depending on size, grade, and thickness. Use the calculator above for instant quotes.