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Australian made custom foam

Foam Cut to Size - Custom Cushions Made in Australia

Any shape, any size, cut to your measurements in our Sydney workshop and delivered Australia-wide.

  • Australian made
  • Cut to any shape
  • Fast delivery or pickup
  • Trusted since 1994

Lead Time

Current custom foam production lead time is approximately 2 business days from order⏱️
Custom foam being measured and cut to size in the Home Upholsterer workshop

Custom cut foam made easy

  • Australian made foam
  • Cut to any shape or size
  • Cushions, beds & more
  • Fast delivery Australia-wide

Step 1 of 4

1. Choose your shape & enter your dimensions:

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
Dimensions (mm)
mm
mm
mm
mm
mm
mm
Next: choose grade

Step 2 of 4

Choose your quantity and foam grade

Next: extras

Step 3 of 4

Choose any optional extras

A bonded polyester fibre (Dacron) wrap gives the cushion a softer, rounder look and makes it easier to slide into the cover. You don't need to allow for it in your dimensions.

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 - C-wrap dacron 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 - C-wrap dacron 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 - C-wrap dacron 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 - C-wrap dacron 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 - C-wrap dacron 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 - C-wrap dacron
Next: review

Step 4 of 4

Review your cushion and add to cart

Shape & size

Change
Shape
Thickness
Diameter
mm
Width (A)
mm
Front width (A)
mm
Depth (B)
mm
Back width (C)
mm
Corner depth (D)
mm
Bottom thickness (C)
mm
Top thickness (D)
mm

Foam

Change
Grade
Application

Extras

Change
Dacron wrap
Quantity

Help for this step

Step 1 of 4

Measuring & sizing

Choose the closest shape. Your foam is generally larger than the cover size. For a fuller cushion, add 5-10mm to width/depth where possible.

Measuring & sizing notes Thickness notes

Choosing foam grade

Choose the closest use in the application field. We will mark the grades suited to the job, then you can choose by the feel you want.

Foam grade notes

Dacron & finish

Dacron gives a smoother, rounder finish and helps the insert slide into the cover. It is a finish layer, so do not reduce the foam size for Dacron.

Dacron & finish notes

Delivery and suitability

Template or irregular profile? Send a dimensioned drawing or a physical template and we will quote it.

custom cut foam delivery FAQs
View foam ordering FAQs

 Previous Projects

Fast Dispatch

Quick production and dispatch across Australia.

Australia Wide Delivery

Reliable shipping to your door or nearest depot.

Expert Customer Service

We're here to help with advice and support.

Trusted Since 1994

Over 30 years of foam experience you can rely on.

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

At Home Upholsterer, we cut foam to your exact size and shape. Every cushion is made to measure in our Sydney workshop using Australian-made foam and delivered Australia-wide. With over 30 years of foam experience, we help you choose the right grade, density and thickness for cushions, sofas, mattresses and outdoor seating, then cut it to your measurements.

Foam Types Available

Choose from our full range of 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 the foam calculator above to design your cushion, choose the density and shape, and check your price before you buy.

Cut to Size Foam FAQs

Measure the inside of your cushion cover seam-to-seam, in millimetres. For a fuller cushion, add 5-10mm to the cover measurements where the fabric has enough give.

Read the full measuring guide.

Match the old cushion thickness if it sat well in the cover. Seat cushions usually need enough thickness to support weight without bottoming out; back cushions can often be softer or thinner.

Read the full thickness guide.

Start with the application field in the calculator. Sofa seat cushions commonly use N30-130 or N31-190, firmer high-use seats may suit H35-200, and back cushions often suit N23-130. Outdoor cushions need dry-flow foam when they will get wet.

Read the full foam grade and density guide.

We don’t offer pre-made foam sample packs, but you can order small pieces in a range of foam grades if you’d like to compare a few options before purchasing. Some customers also choose to order one full-size cushion first, so they can test the feel and suitability before ordering the rest of their set.

Dacron wrap gives the cushion a smoother, rounded finish and helps the insert slide into the cover. It is a finish layer, not a reason to reduce your foam measurements.

Read the full Dacron wrap and foam overlay guide.

We cut foam to size in our Sydney workshop and ship Australia-wide. Larger cushion sets and unusual shapes can take longer because each piece is made to measure.

See all delivery and ordering FAQs.

How to measure & order (video) Technical brochure (PDF) Foam flow chart (PDF) All foam FAQs

Foam Grade Reference

Density, firmness, hardness and typical applications for every grade we cut to size. Australian-made indoor, commercial FR and outdoor grades, with 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, marine

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. Specs are sourced from the supplier Open Cell Flexible Foam Technical Brochure (2025).

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