The foam you choose has a major impact on comfort, appearance and how long your cushions last. Whether you’re replacing tired sofa cushions at home or specifying foam for commercial seating, selecting the right grade ensures you get the support and durability needed for everyday use.
This guide will help you understand which foam suits which project, so you can make the right choice the first time.
How to Choose Foam for Seating
There are three key factors that determine performance and comfort:
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Density – how much foam material is in each cubic metre
- Higher density foam contains more foam and fewer air pockets
- It holds its shape, firmness and support for longer
- Higher density costs more because you are literally getting more foam for your money
-
Firmness (Hardness) – how soft or supportive the foam feels
- Measured in Newtons
- Firmness is about comfort preference, not how long the foam will last
- A foam can feel firm and still break down quickly if the density is too low
-
Thickness – how deep the cushion is
- Deeper cushions compress further and can feel softer while still providing support
- Thin cushions need a firmer foam to avoid bottoming out
- Rule of thumb: the thinner the cushion, the firmer the foam grade required
Understanding these three factors together will help you find the right balance of comfort, support and longevity.
Recommended Foam Grades for Seat Cushions
| Application | Recommended Foam Grade | Feel and Performance |
| Everyday residential seating | N31-190 | Medium firm support for most sofas and chairs |
| Deep seating with a softer feel | N30-130 | Softer cushioning for thick seat bases |
| Heavy duty residential seating | H35-200 | High resilience and longer lifespan |
| Commercial seating – fire retardant | HR36-160 (Medium) or HR40-230 (Firm) | Engineered for high traffic environments |
Recommended Foam Grades for Back Cushions
| Application | Recommended Foam Grade | Notes |
| Supportive residential backrests | N23-130 | Most common choice for sofa backs |
| Decorative scatter cushions | Fibre fill or crumbed foam | Soft comfort, not for full back support |
| Commercial backrests – FR rated | HR36-100 (Soft/Medium) or HR36-160 (Medium) | Comfort and compliance for public seating |
Explore our wide range of foam grades available by the full sheet here:
https://www.cutfoam.com.au/shop/category/foam-fillings-open-cell-foam-sheets-indoor-outdoor-172
Dacron Fibre Wrap
Polyester fibre wrap (also known as bonded polyester fibre or Dacron) enhances cushion comfort and presentation by:
- Creating a plush, rounded finish
- Softening edges so they don’t show through the cover
- Making cushions easier to slide in and out of fabric covers
You can select Dacron wrapping as an add on inside the Cut Foam Calculator.
Or purchase fibre separately:
- By the metre for DIY projects
- In bulk rolls for upholstery workshops
Explore Dacron and padding materials:
https://www.cutfoam.com.au/shop/category/foam-fillings-padding-filling-143
Crumbed Foam Filling
Crumbed foam is made from high quality upholstery foam offcuts, shredded to create a fill that offers both comfort and structure. It works especially well when replacing old polyester or feather filled cushions, providing a plush look with more support and much less daily maintenance.
Ideal for:
- Loose back cushions
- Soft lounge cushions that need lasting loft
- Bean bags and large floor cushions
Browse crumbed foam:
https://www.cutfoam.com.au/shop/category/foam-fillings-crumbed-shredded-foam-filling-183
Ordering Custom Foam Cut to Size
With our Cut Foam Calculator, you can enter your measurements and if you select the application it is being used, you will get live recommendations for the ideal grade for your project. Every piece is cut accurately for a clean, professional result.
Start your order:
https://www.cutfoam.com.au/cutfoam
Replacing cushions or designing a new seating project has never been easier. If you need assistance selecting the right foam grade, our Sydney based team is here to help.
Australian made foam. Fast delivery Australia wide. Trusted by upholstery professionals and DIY customers alike.