Foam Cut to Size & Shape

Custom Foam Made in the UK Since 1983 - Free Next Working Day Delivery

22 Foam Shapes - Choose Yours

Select from 22 standard shapes below, or pick Odd custom shape for fully bespoke cutting from your template or dimensioned drawing. Click a shape to start your quote.

Square / Rectangle cushion Chair cushion Bullnosed cushion Rounded edge cushion All rounded cushion Trapezium/Bolster Window/dining seat Clipped window seat L cushion Curved L cushion T cushion Curved T cushion 2 part chair cushion 4 part lounge cushion Boat Mattress 5 sided trapezoid (polygon) 6 sided trapezoid (polygon) Wedge Triangle Equilateral triangle Clipped bolster / Corner cut mattress Semicircle cushion Cylinder / Bar stool Odd custom shape

What Is Foam Cut to Size?

Foam cut to size is a custom-manufacturing service where a piece of foam is made to a customer's exact specified dimensions and shape, rather than bought as a standard pre-cut sheet. At eFoam, foam cut to size is manufactured on demand in our Bilston UK factory using industrial CNC and hand cutting tools, then dispatched within one working day on a free 24 hour courier to Mainland UK.

Foam cut to size is used wherever a standard rectangular foam sheet won't fit: replacement sofa cushions, custom mattresses, boat berths, motorhome conversions, window seats, bay windows, packaging inserts for fragile goods and bespoke acoustic panels. Because every cut is made to order, you choose the exact size, shape, foam grade and density to match your project.

Foam Grades - At-a-Glance Comparison

A quick reference to help you choose. Hover or tap a grade name on the full foam grades page for densities, firmness ratings and BS standards compliance.

Need help choosing? Call us free on 0800 0439990 or email info@efoam.co.uk. You can also order foam samples to feel the density and firmness before committing.

Replacement Sofa Cushion Foam

eFoam is one of the UK's most popular suppliers of replacement sofa cushion foam. Every cushion is cut to your exact size and shape from our Bilston factory, restoring comfort and support to tired or sagging sofas without the cost of replacing the whole suite.

For the best fit, remove the old foam from the cover and measure the cover seam to seam - don't measure the old foam itself, as used foam loses shape over time and will give you the wrong size. Add 10–25mm to the depth depending on cover material so the new foam sits snugly without bulging.

For sofa seat cushions, Reflex (high density firm polyurethane) is the most popular choice for durability and support. For back cushions, Medium grade is more comfortable. We recommend adding stockinette to all sofa cushion replacements - the soft tubular sleeve makes inserting the new foam into your existing covers much easier.

If you'd prefer not to handle the foam yourself, our foam cushion refill service lets you send us your covers - we cut the foam, insert it, and ship the finished cushions back to you ready to use.

Foam Cut to Shape

As well as cutting foam to size, eFoam cuts foam to shape. This matters when a standard rectangle won't fit - for awkward alcoves, curved cushions, angled benches, marine berths, custom mattresses or specialist packaging inserts.

Popular cut to shape options include:

• Bullnose cushions - one rounded edge, ideal for window seats and bay windows.


• L and T cushions - for corner sofas, sectional seating and chaise lounges.


• Trapezium foam - for angled benches, dinettes and bay seating.


• Wedge foam - for orthopaedic seating, posture support and bed wedges.


• Cylinder & bolster foam - for bar stools, neck rolls and decorative cushions.


• Boat & narrowboat mattresses - cut to your V-berth, cabin or dinette dimensions.


• Odd custom shape - for anything that doesn't fit the 22 standard options.

For unusual shapes, choose Odd custom shape from the 22 shapes above, then send us a template, dimensioned drawing, photo or sample. Our team will confirm measurements and produce your piece to the millimetre.

Where People Use eFoam's Cut to Size Foam

Our customers use custom cut foam for an enormous range of projects. The most common:

• Sofa & armchair cushion replacement - tired, flat or split cushions restored to like-new with a precision cut to fit your existing covers. Add stockinette for easy insertion.


• Campervan, caravan and motorhome cushions - bench, rock-and-roll bed and pop-top mattresses cut to fit your conversion.


• Window seats, bay windows and bench seating - rectangular or shaped foam cut to your alcove dimensions.


• Boats and narrowboats - V-berths, dinette cushions and shaped marine seating. Reticulated reflex foam available for damp environments.


• Dining chair pads and kitchen banquettes - soft to firm grades depending on use frequency.


• Static caravan and holiday-home cushions - firm reflex foam to handle heavy use.


• Garden furniture cushions - reticulated dry-fast foam for outdoor seating that gets wet.


• Packaging and protective inserts - closed-cell EFP30/EFP45, Plastazote, Ethafoam and Jiffy Foam for transport and storage of fragile goods.


• Acoustic foam panels - Pyrosorb-S Class 0 fire-rated foam for studios, churches, sports halls and home theatres.


• Dog beds and pet cushions - cot-safe medium grades cut to fit any pet bed frame.


• Church pew cushions - long flat strips with optional fire-rated grades for places of worship.

How to Order Foam Cut to Size - 5 Simple Steps

1. Step 1 - Select your shape. Pick from the 22 shapes above, or choose Odd custom shape for fully bespoke cutting from your template or drawing.


2. Step 2 - Enter your dimensions. Measure the cover (not the old deflated foam), in mm, cm or inches. Hover the "touch for more guidance" button for help.


3. Step 3 - Get an instant quote. Click "get price", select your foam grade. Unsure? Contact us for free advice.


4. Step 4 - Add optional extras. We recommend stockinette for upholstery and sofa cushion replacements - it makes inserting the new foam into the cover much easier. Dacron wrap adds a soft outer layer for a plumper look.


5. Step 5 - Place your order. Pay securely online. Orders are dispatched within one working day on a free 24 hour courier to Mainland UK.

Why Choose eFoam for Foam Cut to Size?

• Cutting foam since 1983 - over 40 years of experience from our own ISO 9001 certified UK factory in Bilston, West Midlands.


• Made in the UK, dispatched within one working day - no overseas outsourcing, no waiting weeks.


• Free next working day delivery on all Mainland UK orders. VAT included on every quote. No hidden charges.


• All foam meets or exceeds UK fire safety standards - BS 5852 (upholstery), BS 7177 (mattresses), BS 476 (Class 0 fire rating).


• The widest range of foam in the UK - over 15 polyurethane grades plus memory, acoustic, fire-rated, closed-cell and recycled foam.


• Rated ★ 4.87 from 32,664 verified customer reviews on reviews.co.uk. Read what real eFoam customers say.


• Free expert advice - freephone 0800 0439990, 8am to 5pm Monday to Friday. Talk to people who actually cut foam, not a call centre.

Foam Cut to Size Frequently Asked Questions