Before you start cutting, determine what general shape and size you want your final cut cushion to look like. If your new cushion will be a standard rectangle or square, then accurate measurements and a good piece of foam are all you really need. However, if you’re making a round foam cushion or your desired shape is irregular, you’ll want to cut the foam using a pattern and should follow the simple steps below:
#1. Measure Your Starting Shape
Decide on a final general outer shape for your new foam cushion or pillow. The best way to do this is by using the existing cushion cover if you still have it. Measure from hem to hem to get the outer dimensions and add an extra inch or so to the length and width so your starting foam is large enough. You should be prepared with your new piece of foam in the desired thickness ready to be cut into your specific shape. From there, you can begin measuring out the correct size to make a pattern, ideally on a large piece of kraft paper or bolt of fabric.
#2. Make a Pattern
To begin making a pattern for a cushion, get a large piece of kraft paper or a large bolt of cloth. You can even tape together a few sheets of newspaper in a pinch. Cut the material out based on the general measurements you made in step one plus 3-5 inches around all the outer dimensions. Then lay the old foam or cushion cover onto the pattern and trace the shape slowly and carefully using a Sharpie or other permanent marker. If you find it easier, you can also place the pattern paper or cloth directly on top of the furniture you are going to make the cushion for and trace it that way.
If you are sending the pattern to FoamOrder.com or a professional upholsterer, be sure to note details directly on to the pattern, such as top vs. bottom (if necessary), where the zipper should go and the thickness of the cushion you intend to buy or make. Finally, cut out the pattern shape along the lines you’ve made.
#3. Mark the Foam
Now that you have a pattern and a large piece of foam ready to be cut, you can prepare the new foam for cutting. Place the pattern on top of your new foam, follow the pattern with a Sharpie and draw a guide for your cuts onto the material you’re working with. You can use pins or push pins to hold the pattern in place while marking so it doesn’t slip around during this part of the process. When this step is complete, you should see the outline of your new cushion in the correct thickness ready to be cut.
#4. Cut the Foam
Once your marks are in place, you are ready to begin cutting your new foam. Remember that perfection isn’t required when cutting foam to a pattern; the foam naturally may expand or compress into the shape of your cushion cover and will also often be covered in Dacron or other batting. A variance of up to a quarter-inch is fine as you cut your foam. Depending on how complex your pattern is, you can use the tools mentioned above for cutting. The larger or thicker the piece, the more it will make sense to use a foam saw rather than an electric or plain serrated knife.
#5. Test the Shapes and Modify as Needed
Once you’ve finished cutting everything out, test it all around the piece(s) of furniture where you’re adding new foam padding or inserts. Make any necessary adjustments so your shapes fit correctly and don’t cause problems with the way your cushion fits into place if they don’t line up properly.
Because foam is generally inexpensive, if you’ve made your foam piece too small, you can start over again or glue on an additional piece of foam using foam glue. Remember that an outer layer of batting can hide seams as long as the foam is glued together thoroughly. If your cut is too large, you can easily trim it down with the tools identified above.
#6. Add the Batting
After making any necessary adjustments to your foam pieces, you generally want to apply a layer of polyester, cotton or wool batting to your foam. The batting serves two purposes. First, it allows the foam to easily slip inside the cover. Second, batting provides the puffy, comfortable look that most interior cushions have. We recommend a batting “book wrap” for standard cushions, although some people like to apply batting to all sides of the cushion.
To make a cushion book wrap, start by cutting the batting to a size slightly larger than the combined size of the top, bottom and front of your cushion. Then wrap the batting around these three sides before gluing it on. Finally, trim it to the exact size of your cushion with sharp household scissors. You can attach the batting with a light coating of any spray glue.
