Foam for your furniture upholstery is a very important element. Whether you are planning to restore your old sofa, make some new cushions, or design a new piece of furniture with plush seating – you need to have the right foam. Having foam is one thing, but to have the skill to accurately cut the foam is something you also need to have. This seems like a simple task but it’s actually a lot more than it seems. You will need the right tools, have some working experience, and know the right techniques to ensure an accurate upholstery foam cut piece.
To assist you with this, we’ve included a step-by-step guide on how to cut furniture upholstery foam. So, stay with us, and you might learn something extraordinary for your DIY home projects.
Types of Upholstery Foam
Before you start cutting the foam, you need to know its types. Foam comes in a variety of thicknesses and densities, each offering personalized comfort. These are some common types of foam for Sofa upholstery.
- Low-Density Foam: This is flexible and very soft. It’s mostly used to cushion furniture seats, especially the areas that need less support.
- Medium-Density Foam: They are mostly fitted in the armrests or inside cushions. They provide the optimal support and comfort for the seater.
- High-Density Foam: These are used mostly for sofa seat cushions as they are quite firm and thick. You can get firm support with this highly durable foam.
It’s actually the foam type that determines which cutting technique to use. High-density foam demands the use of much sharper tools and requires high-precision cutting compared to low or medium-density foams.
Tools Needed For Cutting Upholstery Foam
Most of you might think that I can cut the upholstery foam for custom made furniture with just a pair of scissors or a sharp knife. In reality, you need special tools for cutting foam. The right tools allow the cut foam piece to have a finished appearance. You will need these tools.
- An Electric Carving Knife
- A Utility Knife
- Foam Cutter
- Ruler
- Marker
- A Stable Cutting Surface
Step By Step Guide To Cutting Upholstery Foam
There are only two main steps to cutting upholstery foam. Follow our instructions to achieve a perfectly finished foam cut.
Prepare Foam For Cutting
The first step is the preparation of your foam to ensure the right cut. These are the steps you need to follow to prepare the foam.
- Measuring & Marking: Use a ruler to measure the dimensions needed for your upholstery. Then, use a marker to outline the area that will be cut.
- Place It Securely: Once marked, place the foam for cutting on a stable surface. Some foam rolls, especially for high-density ones, lay them down flat for a few hours to unroll fully.
- Securing The Foam: Foam tends to slip and shift during the cutting process, especially the larger and high-density pieces. Use weights or clamps to keep them secured in one place before cutting.
Cutting The Foam: Various Techniques
The next step is to start cutting the upholstery foam. The technique for cutting the foam depends on which cutting tool you use. These are the different cutting techniques that you can use.
Cutting Foam With An Electric Carving Knife
This tool is ideal for cutting the high-density foams that are much thicker.
- Hold your electric knife perpendicular to your laid-down foam and place it on the marked line.
- Turn the knife on and press it gently into your foam. Let the serrated blade edge do its job. Do not put pressure on it; the foam will start to be cut smoothly.
- Start moving the knife along the marked line. For thick foam, cut the foam into small sections instead of cutting it all in one go.
- If there are any uneven edges for the foam, use the blade to adjust them and trim off any excess foam.
Cutting Upholstery Foam With A Utility Knife
For low-density and medium-density foams, you can use a simple utility knife. However, make sure that it is sharp enough to cut the foam easily.
- Extend the blade to its full length to ensure a deep foam cutting.
- Use the knife to make a slightly cut line across the marked line on the foam. This creates a shallow groove.
- Now, make multiple passes along these shallow grooves. Each pass will deepen the cut, preventing the risk of foam tearing apart and giving a cleaner edge.
- Once the foam is cut, use the blade along the edge to smoothen it.
Cutting Upholstery Foam With A Foam Cutter
Foam cutters are specially designed tools used only for making detailed cuts.
- First heat the foam cutter, if it works by heating up.
- Pass the cutter along the marked line softly and steadily with gentle pressure. The heat of the cutter will start to melt the foam, leaving a finished edge.
- To prevent mistakes, do it slowly and do not rush the process. The slower the cutter passes, the more precise the cut foam.
Helpful Tips For Cutting Upholstery Foam
While our foam-cutting techniques might be helpful, these additional tips will surely be. Follow these tips for more refined upholstery foam cuts.
- Always use a sharp knife to tear the foam. These tears leave jagged edges that are hard to fix.
- If this is your first time cutting foam, we recommend practicing first on a scrap foam piece.
- If the foam is thick, do not cut it all in one go. Cut in sections, as this offers a cleaner cut.
- Make sure to use a piece of wood or a ruler to use as a guide to make straight cuts. This is especially true when using a utility knife.
- Once the foam is cut, you can use sandpaper or a filer with fine teeth to fix imperfections in the edges.
Final Words
You can easily cut your upholstery foam, a task that seems hard, with just the right tools, a bit of practice, and the right techniques. Follow the step-by-step instructions on how to cut upholstery foam in this guide for various foam types with appropriate cutting tools.
Patience and preparation are key to achieving a precise and clean upholstery foam cut. Use sharp tools and make adjustments as you progress. With this guide, you will not need to rely on an expert for upholstery foam cutting.
