Foam & Cushions: 101
A guide to selecting the appropriate foam, fabric, & cushion style for your hospitality projects
BDNY 2023
OBJECTIVES
Understand different types of Foam, Fabrics, and Cushion Construction
Know how to design a cushion for the particular space it will occupy
Be able to read and write a specification to design and procure the cushions you need
ABOUT FOAMORDER
Founded in 1999. We have 20+ years of experience fabricating custom cushions for home and commercial applications
We have served over 150,000 customers with unique cushion orders
Over 100 years of collective experience among our production/purchasing team
We can make virtually any cushion solution for almost any application for any size order
From one cushion (damage/replacement) to thousands of cushions
Indoor or outdoor
Traditional foam or organic solution
Custom solutions (cut to pattern, acquire fabrics, difficult challenges)
Proud partner of high-end hospitality brands and ownership groups
SELECTING FABRIC
Color, Feel, Availability, Cost
The four most important factors when making a selection
Make sure your fabric is available
Do you need more than just enough for this single order (attic stock)
Durability
Always use contract grade fabric for high-use areas. Generally, a fabric that has a durability rating of at least 50,000 double rubs
Indoor vs. Outdoor
Will the fabric be exposed to rain, moisture
Manufacturers will specify if fabric is designated for indoor or outdoor use
Fabrics with Pattern
Specify the pattern/stripe direction
Railroad vs. not
SELECTING FOAM & INSERTS
Indoor Foam Options
Description Density Longevity*
HR Foam
(High Resiliency)
Conventional Foam
Highest quality polyurethane foam, required for high-use areas 2.6-2.8 lb/ft3 15-20 years
Lower quality, more useful for “display” cushions 1.6-1.8 lb/ft3 3-5 years
Latex Foam
Organic material made from rubber tree sap 5-6 lb/ft3 10-15 years
*Longevity estimates are for residential high-use applications
SELECTING FOAM & INSERTS
Outdoor Foam
Reticulated (open cell) foam allows water to pass through the foam and dry quickly
Density is usually 1.6-2.0 lb/ft3
Rougher to the touch, somewhat less comfortable than traditional foam
Available in 3 firmness options (soft, medium, firm)
SELECTING
FOAM & INSERTS Recommended Firmness Options
The ILD is a rating given to specify the firmness of foam. Technically, it is the weight required to depress a 7”x7” area by 1”. The higher the ILD, the firmer the foam.
ILD Seat Thickness Back Thickness
BATTING & FINISH
Batting is used to fill out the cover and prevent wrinkles, and to provide a more luxurious look and comfortable feel.
Dacron Bookwrap
Traditional cushions have one layer of dacron wrapped around the top & bottom, and the front edge
Wrap All Sides
Cushions that have multiple faces exposed should have dacron covering every face
Other Options
Double dacron, additional crowning, organic wool or cotton batting
ENVELOPES & PILLOWS
Additional options to achieve a more luxurious, full look and feel.
Thicker, Finished Look
A fuller, more luxurious finish, usually with stronger crowning
How It’s Made
Down/feather or poly fill envelopes can provide a similar look at different price points
Pillows
A pillow style back-cushion is the softest option and great for seating areas with larger depth
SPECIAL APPLICATIONS & ALTERNATIVES
Organic Options
Organic latex foam (made from the sap of rubber trees)
5 firmness/ILD options
Organic wool, organic cotton
batting
Hemp fabric
Latex-based glue
CMHR/Fire Retardant Foam
Combustion Modified High Resilience foams are primarily used in the commercial furniture industry when the strictest fire code standards are required.
Hotels, schools, livery and the hospitality sector in certain applications
Often specified and rarely required
CUSHION CONSTRUCTION DETAILS
Upholstered vs. Loose
Upholstered cushions that are firmly attached to the seating or a hard medium require an upholsterer on site.
Loose Cushion Banquette
Cushion is used as a bench but not affixed to the wood/furniture. More easily removed and/or replaced. Can be affixed with velcro or hooks/straps.
Fixed Booth Installation
Requires an upholsterer on site to construct. Better for long-term installations with more durable materials (leather).
CUSHION CONSTRUCTION DETAILS
Box, Plush, Knife-Edge Cushions
Cushion Finish Options
Box Cushion
A box-style cushion is a traditional sewing style with uniform thickness. It is most important to note the “boxing” dimension, which is the distance from seam-to-seam.
Crowned Cushion
Crowned cushions must be sewn to allow for additional crowning/fill. It is important to note the seam-to-seam dimension AND the total thickness.
Knife-edge
A pillow style back-cushion is the softest options and great for seating areas with larger depth. These types of cushions often lack structure and can be less comfortable.
CUSHION CONSTRUCTION DETAILS
Seam Options
Seams are a decorative element to cushions.
Welt Cording
A simple fabric-covered cord that follows the seam of a cushion. It creates a professional tailored look.
Top Stitching
Creates a more contemporary or modern look by showing the sewing line on the outside of the cushion.
French Seam
Essentially two seams stitched together. Provides extra strength and can be enclosed or exposed.
Waterfall
When a seam is absent around an edge. The fabric travels around the foam in one direction without a seam.
CUSHION CONSTRUCTION DETAILS
Means of Attachment
Cushions can be secured in many different ways:
Velcro
Can be sewn into a cushion as a way to secure it to furniture, built-in seating, or to an adjacent cushion
Chair ties
Provide a secure hold and can be left exposed for a decorative touch
Clips & Rings
For hidden attachments, cushions can be constructed to include clips that attach to built in rings
CUSHION DESIGN CHECKLIST
What to clarify with your design, procurement and vendor team:
Fabric
How many double rubs?
Is there a pattern? What direction?
Is this rated for indoor/ outdoor use?
Foam
Indoor or Outdoor Foam?
What is the density and ILD rating?
Where is Dacron required?
Are the foam and overall dimensions specified?
Construction
Will the cushions be upholstered or loose?
Are the cushions sewn with a box style, are they plush, or do they have a knife-edge?
Is the yardage required available? What is the fabric width? Have I ordered a swatch?
Is there a pillow style filling or any down envelope requirement? Is there a requirement for Fire Retardant foam or Organic material?
What type of seam should be used?
How will the cushions attach to the seating area?
Where will the zipper go?
SAMPLE SPECIFICATION
Descriptive name
Style of cushion (Box)
Stitching detail
All fabric details
Foam type
Firmness
Seam-to-seam and finished dimensions
Notes that finished size is due to dacron wrap