UK Foam Grades, Types & Datasheets — Reflex, Memory, Reconstituted, Pyrosorb, Plastazote and more

Most foam choices come down to one question: what will the foam actually do? A cushion that sits on a sofa for ten years takes a different grade from one that sits in a campervan getting rained on, or a pad an elderly Labrador sleeps on every night, or a sheet of foam protecting a sound desk from echoes. We stock the full UK range and have done for over 40 years, with every grade backed by a downloadable datasheet you can hand to your upholsterer, architect, or building control if needed.

Below you'll find every grade we cut, grouped by what it's made of and what it does. If you know exactly what you need, the table is yours: every row has a datasheet, a link to the relevant product page, and notes on what it's typically used for. If you're not sure, use the Find Your Foam tool just below: select what you're making or repairing, and we'll highlight the grade generally recommended.

Quick guide: which foam for which job?

A condensed reference for the most common UK use cases. The grade we recommend is what UK trade and retail buyers most often choose after we've worked through their job over the phone. Use the Find Your Foam tool above for an interactive version that highlights the grade in the full table below.

How to Choose: Open-Cell vs Closed-Cell, Density vs Firmness

Open-cell vs Closed-cell: Polyurethane foams (Average, Medium, High Firm, Severe, Reflex, Memory, Cot Safe) are open-cell foams, the bubbles inside are interconnected, so air passes through. That's what makes them soft, springy and comfortable. Polyethylene foams (Plastazote, Ethafoam, EFP30, EFP45) are closed-cell foams, each bubble is sealed. That's what makes them firmer, water-resistant and durable in commercial and industrial use. Neither is "better"; they do different jobs.

Density vs Firmness: These are different properties that are often confused. Density (kg per cubic metre) is how much material is packed into the foam, and it correlates with how long the foam will last under repeated compression. Firmness is how much force is needed to compress the foam, and it determines what the cushion feels like to sit on. A high-density foam can be soft (Reflex Medium) and a low-density foam can be firm (some packaging grades). For seating, you want both high density (longevity) and the right firmness for the application.

Why grade matters more than thickness: A common upholstery mistake is over-specifying thickness to compensate for poor-quality foam. Three inches of High Firm SF38 outlasts and outperforms six inches of cheap polyether by a wide margin. Get the grade right first, then choose the thickness that suits the cushion depth.

Polyurethane Foam Family

Polyurethane (PU) foam is the most widely used flexible foam material, made by reacting polyol with diisocyanate. Available in a wide range of densities and firmnesses, it's the workhorse of UK upholstery and bedding. Common applications include:

• Sofa, armchair and dining seat cushions
• Mattresses and mattress toppers
• Headboards and bed bases
• Dog and pet beds
• Campervan, narrowboat and static caravan conversions
• Insulation (acoustic and thermal, in specialist grades)
• Leisure and fitness equipment

Memory Foam

Memory foam (also called viscoelastic polyurethane) is a specialist PU foam developed in the 1960s for NASA. The viscoelastic chemistry causes it to soften with body heat and mould to the shape of the sleeper, then slowly recover when pressure is removed. It excels at relieving pressure on joints and bony prominences.

Common applications:

• Mattress toppers (the most popular use)
• Pillows and cervical supports
• Orthopaedic dog beds (paired with a firmer base)
• Wheelchair and pressure-relief cushions
• Medical and care home applications

Memory foam is rarely used as a complete mattress on its own (it allows the sleeper to sink too far without a supportive base). The most common spec we cut is 2" of memory foam bonded to 3-5" of Reflex foam or High Firm foam.

Polyethylene Foam Family

Polyethylene (PE) foam is a closed-cell foam made from expanded polyethylene plastic. The sealed cell structure makes it durable, water-resistant, and able to absorb impact without compressing permanently. It is firmer than polyurethane and not suitable for comfort applications, however it's the right material for:

• Protective packaging (electronics, instruments, fragile items)
• Sports and water-sports equipment
• Automotive applications (linings, gaskets, seals)
• Flotation and buoyancy aids
• Thermal and acoustic insulation
• Cosplay armour and theatre props

Three main variants in our range:

• EFP30 / EFP45 Closed Cell — rigid extruded closed-cell polyethylene in two densities, non-absorbent and waterproof, used for industrial and commercial packaging, insulation and flotation. FR variant available.
• Plastazote LD33 / LD45 — nitrogen-expanded cross-linked PE, available in 10 colours, with or without self-adhesive backing.
• Ethafoam / Stratocell — non-cross-linked PE, ideal for heavy-item packaging in transit.

How to choose the right foam: a four-step process

Same process we walk through with customers on the phone. Use the Find Your Foam tool above for an interactive version, or follow these four steps if you prefer to work it out yourself.

1. Identify your project type: Decide which foam family suits the job. Polyurethane (PU) for indoor cushions, mattresses and pet beds. Polyethylene (PE) for packaging, outdoor and industrial applications. Specialist grades for fire-rated commercial seating, acoustic treatment, anti-static packaging, or cot mattresses.
2. Estimate the load and use frequency: Light use such as headboards or occasional cushions can take lower-density foam. Daily use such as sofas, beds and pet beds needs mid to high density (SF38 or above). Heavy commercial use such as church pews, bar stools or wheelchair seats needs the densest reconstituted chip foam (SFR6 or SFR9).
3. Select the foam grade: Use the Find Your Foam tool at the top of this page to highlight a recommended grade, or cross-reference the Quick Guide table. Memory foam should be paired with a firmer base layer rather than used alone. For outdoor cushions, use reticulated water-drain foam (aquatic filter grade).
4. Choose the thickness: Sofa and armchair cushions: 3 to 5 inches. Bed mattresses: 4 to 8 inches. Dog beds: scale with dog size, 3 to 6 inches typical. Window seats: 1 to 3 inches with high density (Severe SF50) for thin profiles, or 4 inches and up with High Firm (SF38) for deeper banquette seating. Crate beds and raised dog beds: 2 to 3 inches because the frame provides support.

If you'd rather just talk it through, the contact page reaches our friendly & knowledgable team directly.

Frequently asked questions about foam grades

Cut to size, cushion refilling, and bespoke shapes

Every grade above is cut to your exact size or shape in our Bilston factory. The standard service is foam cut to size: pick a grade, send us your dimensions or upload a template, and we ship the next working day. For existing covers that have outlasted their foam, our cushion refill service takes your empty cover and returns it ready to use. For trade and bulk orders, see our trade foam programme for volume pricing.

If you're still unsure which grade is right for your project, the contact page reaches our Bilston team directly and we usually come back to you the same working day. Tell us what you're making, who's going to use it and how often, and we'll work out the grade in a five-minute phone conversation.