Foam & Cushions: 101

Foam & Cushions: 101 A guide to selecting the appropriate foam, fabric, & cushion style for your hospitality projects

BDNY 2023

Nate Bowyer | nate@foamorder.com | (510) 426-5579

TABLE OF CONTENTS 1.

About FoamOrder

2.

Fabric

3.

Foam & Inserts

4.

Cushion Construction

5.

Cushion Design Checklist

6.

Conclusion

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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

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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

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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

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SELECTING FOAM & INSERTS Indoor Foam Options Description

Density

Longevity*

Highest quality polyurethane HR Foam (High Resiliency) foam, required for high-use areas

2.6-2.8 lb/ft3

15-20 years

Conventional Foam

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

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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)

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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

Soft

20-25

6”+

4”+

Medium

30-35

4-6”

2-3”

MediumFirm

40-45

2-4”

2” or less

Firm

50+

2” or less

Not recommended

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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

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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

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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

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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).

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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.

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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.

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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

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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?

Is the yardage required available? What is the fabric width?

Have I ordered a swatch?

Foam Indoor or Outdoor Foam?

What is the density and ILD rating?

Where is Dacron required?

Are the foam and overall dimensions specified?

Is there a pillow style filling or any down envelope requirement?

Is there a requirement for Fire Retardant foam or Organic material?

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?

What type of seam should be used?

How will the cushions attach to the seating area?

Where will the zipper go?

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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

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NATE BOWYER Director of Business Development

nate@foamorder.com 510-426-5579

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