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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

Cut Foam Calculator

1. Choose your shape & enter your dimensions

a) Choose your shape:
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?

c) Select your foam grade:



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

Cushion specifications
Shape:
Thickness
Diameter
mm
Width:
mm
Front width (A)
mm
Depth (B)
mm
Back width (C)
mm
Corner depth (D)
mm
Bottom thickness (C)
mm
Top thickness (D)
mm
Application
Foam grade
Foam wrap
Quantity:
Price breakdown
Foam total
Dacron wrap total
Price per cushion Includes foam + dacron wrap
Grand total
Order notes (optional)

Added to cart

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

 Previous Projects

Cut to Size Foam FAQs - Sizing, Grades and Delivery

For everyday sofa cushions in residential applications, we generally recommend a heavy duty upholstery foam such as grades N30-130, N31-190 or H35-200, depending on thickness and the comfort you prefer. These hold their shape without sagging and work well for both 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 suits patio, garden or marine cushions that sit out in the weather. If the foam is kept undercover and unlikely to get wet, regular indoor foam will do the job and costs less.

Foam density refers to the weight and durability of the foam, while firmness is how soft or hard it feels to sit on. High density foam is more durable and lasts longer, and it still comes in soft, medium or firm options depending on your comfort preference.

High density seat foams like N31-190, and the commercial grades above it, tend to last the longest. They resist sagging and hold their shape over time, which makes them a good choice for cushions, sofas or mattresses that get daily use.

We don't keep pre-made samples, but you can order small pieces in a few different grades to compare before committing to a full project. The smallest size we can cut is 100x100mm, in your choice of thickness and grade.

You can also order a single finished cushion to live with for a while before committing to a larger set.

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. They're a popular pick 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.

Yes. We cut foam to size in our Sydney workshop and ship Australia-wide, including Melbourne, Brisbane, Perth, Adelaide, Canberra, Hobart and Darwin, plus regional NSW, VIC, QLD, SA, WA, TAS, NT and the ACT. Every order is made to measure and dispatched from Sydney, so you can order custom cushions, mattresses and foam inserts online wherever you are in Australia.

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.

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.

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.

Why Home Upholsterer

Home Upholsterer cuts upholstery foam to your exact size and shape, made to order in our Sydney workshop 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 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 TBC 50% Commercial seating, hospitality (FR rated)
HR36-160 36 Medium TBC 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 TBC Medium/Firm TBC TBC 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.