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We carry only the highest density foam materials available to assure you the maximum comfort and support and long lasting durability that you deserve. Besides offering the very best quality foam materials, our personalized customer service is truly exceptional as indicated by our positive client feedback. We look forward to helping you select the best foam material for your needs and restoring the comfort and appearance of your valued furniture treasures to better than new condition.
We are delighted to share our 25 years of experience in the furniture reupholstering and restoration business to help you with your foam cushion replacement needs. Your satisfaction with our foam cushion products as well as our customer service is our highest priority. We encourage you to review the valuable and educational content about foam cushion materials on our website. Please feel free to contact us if you have further questions or concerns or need additional assistance in selecting a foam material or measuring your cushions.
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In this section of our webpage we will try to inform you about foam cushion materials that are used in furniture so you may become a better educated foam cushion shopper. If you are new to purchasing furniture foam cushions you will need to learn some basic characteristics about foam materials to assure your satisfaction and help you select the foam material that meets your needs for comfort and durability. Or, perhaps you have purchased replacement foam cushions before and are once again looking to replace the cushions. We hope to provide you with the information necessary to help you in selecting a better foam material this time.
There are many different grades of foam that are available to the Upholsterer or furniture manufacturer for use in furniture foam cushions. This section will explain the rating standards for foam material so that you will have a better understanding of what makes a particular foam suitable for various applications. There are not necessarily "good" foams and "bad" foams. There are, however, good and bad uses for each particular type of foam which determines your level of satisfaction and comfort with your furniture.
If your foam cushion material is older than about 10 years,if it is beginning to have a "rounded" front edge, or if the seat foam doesn't offer you the support you need to feel comforatable, then you are probably ready for new foam.
Foam production technology has made some very significant advances over the past decade. Foams of varying DENSITIES (Quality) and ILD (firmness) ratings are now produced which offer the furniture manufacturer or Upholsterer an opportunity to select a specific type of foam based upon its intended use. Foam is rated according to various performance tests. The results of these tests allow an Upholsterer, or you the consumer, to know how the foam will "feel" and in what ways the specific foam may be used.
I mentioned the "rounded" front edge as a clue to the need for new foam. This effect occurs over time because you tend to use the front of your cushion to a greater degree than the rest of the cushion. As a result, that portion of your cushion becomes worn or compressed faster than the rest of the cushion. Some Upholsterers will use their steamers to restore the foam to its original shape to save you money on replacement foam and reduce your reupholstery cost but this is only a temporary fix and the foam will soon loose its shape again. Another reason that your seat cushions may develop a rounded front edge is that the foam never was the proper density (quality) to be used as daily use seating foam and as a result it has lost its shape in a relatively short period of time.
There are three performance tests that you as a consumer may use to evaluate the quality and suitability of foam materials for your particular application. All foam materials produced and sold in the USA are rated by these standardized tests and sellers of foam materials or cushions should make the ratings available to you so you know what you are buying.
HIGH RESILIENT (HR) foam is what you might think it is. It is a foam material that is produced to offer a longer useful life than non-HR foam. HR foam is often also rated as fire resistant (FR). Tell your Upholsterer that you are concerned about fire safety and long life of your new foam and ask him to verify that your new foam is rated both HR and FR.
If you are purchasing new furniture or reupholstering furniture which will be used in a public setting, most States have Furniture Flamibility Laws that will require you to use HR-FR foam materials. You should insist upon the use of HR-FR foam materials for use in your home furnishings as well, both for the safety concerns and for the longer life they will offer.
The DENSITY rating of furniture foam is expressed as a two digit number which may range from 18-32. There also exists a family of foam materials with density ratings of 17 or less that are primarily used as packing materials but we won't discuss these foam materials here as they should not be used as furniture cushions.
Actually, there is a decimal between the two numbers which makes the density rating of the #18 foam a 1.8 foam. The density rating of the foam material is the best indicator of the quality of the foam. The higher the density rating... the higher the quality of the foam and the longer you can expect it to maintain its shape, loft and support.
In the production of foam, there are two basic ingredients which are the urethane chemical that is the foam, and air. The more urethane that exists in the foam material, the higher its density rating will be. In the above example, the 1.8 rating means that there is 1.8 pounds of Urethane in each cubic foot of foam material. A cubic foot is equal to an area that is 12" x 12" x 12". This particular foam would be rather low in density and would not be a good material to use in seat cushions that are used on a daily basis. It may, however, be suitable for back cushions as back cushions do not need to support your body weight as seat cushions do. Foam materials of a 1.8 density rating may also suffice for furniture that is occasionally used, sleepover mattresses or for short term use applications.
Think about the making of foam in the same way as a loaf of bread is made. If you allow the dough to rise until it won't rise anymore the loaf of bread will be very large and produce more or larger slices of bread. The original little ball of dough has increased in size with the development of air pockets in the dough. The mass of the loaf is larger and will produce more slices of bread but each slice of bread contains a smaller amount of ingredients. The making of foam is very similar in that the foam manufacturer can increase the amount of eurathane in the foam "bun" and restrict the amount that the bun will be allowed to expand to produce a heavier and higher density foam material. Just like the loaf of bread, a lower density foam material will produce more foam material to sell but it will be much lighter than a high density foam material. This is the reason that high density foam materials cost more to purchase. Over the long term the high density foam will preform better and last longer so the additional expense is actually a "better value" than the cheaper low density foam alternative. I always advise my clients to select a foam material with the highest density rating available that has an ILD (firmness) rating that matches their needs.
The INDENTATION LOAD DEFLECTION (ILD) rating is a measure of how much pressure it takes to compress the foam 25% of its thickness. For instance, if your seat cushion is 4" thick and has an ILD rating of 33, it would take 33 pounds of pressure to compress the foam to a thickness of 3". The ILD rating of a foam material will tell you how FIRM the foam is.
Some people like their cushions to be very firm while others prefer a very soft cushion that feels like a down and feather pillow. There are foam materials to match each persons preferences. For sofa and chair seat cushions of a 4-6" thickness I like to recommend a foam material with an ILD rating of at least 30 lbs but not greater than 41 lbs. In this range your seat cushion will provide the support needed for proper seating posture and you will not experience the problem of "bottoming-out" when you sit on the cushion if they are also a high density foam material. To determine the best ILD rating for your seat cushions you must also consider the thickness of the cushion. If your cushions are 4" thick or more you would probably not want to use a foam with a 41 lb ILD rating or greater because your cushions may feel too firm for comfort. If you are replacing the foam cushions in your dining room chairs where the foam thickness is 1-2" thick a 41 lb ILD foam material may be needed to produce the same cushioning comfort as a 30 lb ILD foam material in a 4" thickness.
If you need to replace your sofa or chair seat cushions I would recommend the use of our best HR 3.1 density/ 33 lb (medium-firm) ILD foam material because this is the highest density seating foam available with an ILD rating that is appropriate for chair cushions. Over 90% of our seat cushions for sofas and chairs are made of this foam material. I like selling this foam because I don't have to worry if our client will be satisfied with the quality of this foam and the firmness level and support of this top quality seating foam material is appreciated by the greater majority of our clients. Most of the comments made on our Client Feedback Page are relating to this foam material that was used in making seat cushions for our past clients.
For dining room chairs, where the thickness of the foam is generally lower (1-2"), I often prefer to use our HR 2.8 density/ 41 lb ILD foam material to compensate for the reduced foam thickness if our client prefers a firmer seat cushion. This foam material will produce a seat cushion that is quite firm but not uncomfortably firm for these thinner seat cushion applications. If your seat cushions are at least 1 1/2" thick and you prefer a seat cushion that is not quite as firm as the HR 2.8/41 foam material but not as soft as the foam that came in the chairs when they were purchased our HR 3.1/33 foam material may again be the best foam choice.
I usually use a back cushion foam which is a 2.4 density with an ILD rating of 18. This foam material produces a medium-firm back cushion that is the ideal mate to our medium-firm and firm seating foam materials. Togeather, this combination of foam materials produces the ultimate in seating comfort using foam materials that are of excellent quality. Where a softer back cushion is desired our 1.4 density/ 12 lb. ILD foam material may be substituted. We have also recently added a new foam material to our back cushion foam line. Our new HR 2.6 density/ 28 lb ILD foam material is ideal for use as a back cushion material for dining chairs where the thickness of the cushion is limited to 1-1 1/2". This foam material may also be used as a soft seating foam or for the top and bottom layer of a hybrid crowned cushion to give the cushion a softer surface feel.
Below is a chart which describes most of the different foam materials we stock. Notice how an entirely different ILD (Firmness) rating can be produced using a foam material with similar density ratings such as our HR 2.5 density foam material which is available in a 30,40 or 50 lb ILD rating. This should illustrate the importance of the ILD rating in selecting a suitable foam for your needs. A high density foam is not necessarily the proper firmness just as a firm foam material is not necessarily a high density foam material. It is very important that you know all of the characteristics of a foam material to help you select the best foam type for your application and needs.
You will note that the ILD ratings of the foam materials in the chart range up to 70 lbs. While these very firm foam materials are available and have their specific and appropriate uses I would rarely recommend the use of any foam material higher than a 41 lb ILD rating for seat cushions that are greater than 2" thick.. The 50,61 and 70 lb ILD foam materials may be used for such applications as kneeler cushions or fitness equipment pads where the foam thickness is limited to 1-2" and the higher ILD rating is necessary to compensate for the limited thickness of the foam where elbows or knees will be grating into the foam on a regular basis. We also often recommend these foam materials for motorcycle, snomobile and RV seat cushions.
Many of our clients still have specific questions about selecting a foam type for their replacement cushions or how to measure cushions for replacement foam inserts. While we have tried to answer most of your questions here, we are also happy to help you over the telephone. We hope you will not hesitate to call us or send us an E-Mail to discuss your foam cushion needs if you need more help. We have over twenty years experience in the furniture reupholstery and furniture restoration business and we look forward to helping you select the right foam material for your replacement cushions.
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Cushion wraps are a layer of material that is installed between the foam material and the fabric cover. A commonly used cushion wrap material is DACRON. I always recommend the use of cushion wraps and further recommend that the dacron material be laminated to the foam using special foam glues.
The purpose of the dacron wrap is to soften the sharp edges of the foam to give it a more soft appearance. The dacron wrap also helps to protect your fabric in the event of a liquid spill by allowing the liquid to pass through your fabric and the dacron and settle in the foam. While the spill may keep your foam wet for several days, there will be a barrier between your foam and your fabric which will allow your fabric to dry out rather than continue to soak up the wetness from your foam. Even a dry spill,such as dirt, will have less of a soiling effect on your fabric with a dacron wrap as the dirt will pass through the dacron and settle into the foam.
Another advantage of a dacron wrap is that some fabric backings are somewhat abrasive. Each time you get into, or out of, your chair the fabric and foam rub togeather to some extent. The dacron wrap will eliminate this abrasive action and extend the life of your fabric and your foam. The dacron wrap should be laminated to the foam to prevent the dacron from moving and bunching up inside of your cushion cover. A laminated dacron wrap will likely increase the cost of your foam cushions by $5-15.00 but should be considered a good investment.
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