Which Cushion Wrap Weight Should You Choose? 🤔

The right polyester cushion wrap (Dacron) weight depends on how much loft and softness you want to add to your foam cushion.

👉 Think of polyester cushion wrap this way:

• Lighter weights (2½oz – 4½oz): Best for tight covers or when you just want to soften edges without bulking the cushion. Ideal for dining chairs, headboards, or slim seat pads.
• Medium weights (8oz – 10½oz): The all-rounders. Great for everyday sofa cushions and window seats where you want comfort plus a bit of plumpness.
• Heavyweight (14oz): Maximum loft. Best for oversized cushions, scatter backs, or where you want that deep, luxurious look.

Quick Reference – Loft Guide 📏

• 2½oz → 10mm loft
• 4½oz → 15mm loft
• 8oz → 20mm loft
• 10½oz → 30mm loft
• 14oz → 45mm loft

✅ Top tip: For seat cushions, it’s usually best practice to wrap the top and bottom surfaces of the foam (sometimes the sides too if the cover allows). This keeps the cushion looking fuller and stops sharp foam edges showing through.

One of the most common mistakes when ordering new foam cushions is assuming the foam thickness equals the finished thickness of the cushion. In reality, once you add polyester wadding (Dacron), the cushion gains extra loft – usually 1–2cm per side.

👉 Rule of thumb: Always match the border (edge) measurement of your existing cover with the foam, then wrap it with Dacron. The wadding adds loft, fills the cover beautifully, and gives you that plump, professional finish.

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Why Wrap Foam Cushions in Polyester Wadding? 🤔

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✅ Adds loft & fullness – cushions look plumper and more inviting.
✅ Softens sharp foam edges – no more blocky corners.
✅ Protects your fabric – reduces wear from foam rubbing on the cover.
✅ Improves comfort – a touch of spring without sagging.
✅ Professional finish – upholsterers always use it for sofas, chairs, beds, campervans & boats.

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Tools & Materials You’ll Need 🛠️

• Foam cushion cut to size.
• Polyester wadding (choose the right weight for your job).
• Spray adhesive (foam-safe).
• Sharp scissors or craft knife.
• Flat work surface.
• Optional: stockinette sleeve for a smoother fit inside the cover.

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Choosing the Right Wadding Weight ⚖️

At Foam4U we stock upholstery-grade polyester wadding in five weights, so you can choose the right amount of loft for your project:

• 2½oz – Very light wrap. Just softens edges. Handy for slim cushions or window seats with tight covers.
• 4oz – Light wrap. Adds a touch more fullness without bulk. Great for thinner seat cushions.
• 8oz – Medium wrap. A good balance for everyday sofa or chair cushions.
• 10½oz – Our most recommended weight ✅. Ideal for most seat and back cushions – plump without overstuffing.
• 14oz – Heavy wrap. For scatter cushions, back cushions, or projects needing maximum loft.

👉 Remember: the heavier the weight, the more loft you’ll get. Allow for this when choosing foam thickness to match your cover border.

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Step-by-Step: Wrapping Foam with Dacron

1. Prepare the Foam 🧽

Check your foam matches the cover’s border size. The Dacron will add loft on top.

2. Cut the Wadding ✂️

Roll out the Dacron and cut a piece big enough to cover the foam, leaving a few extra centimetres around the edges.

• Seat cushions: Best practice is to apply Dacron to the top and bottom surfaces only.
• If the cover design requires wrapping around the sides, that’s fine – but you may need extra allowance to keep the fit comfortable.

3. Apply Spray Adhesive 🧴

Always glue the Dacron to the foam. A light mist is enough to hold it in place, stopping it from sliding or bunching inside the cover.

4. Wrap & Smooth 🎁

Place the foam onto the wadding, fold it over, and smooth it flat with your hands.

5. Trim Corners & Excess ✂️

Cut away overlaps neatly at the corners. This avoids bulky lumps when you slide the cushion into its cover.

6. Add Stockinette (Optional) 🧦

Slip a stockinette sleeve over the wrapped foam for a smoother finish and easier insertion into covers.

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Special Note: Upholstering Headboards 🛏️

If you’re wrapping foam for a headboard or wall panel, make sure you cut enough Dacron to wrap all the way around the foam and onto the backboard. This ensures a clean, professional edge once it’s pulled tight and stapled.

Again: always glue the Dacron to the foam first, so it doesn’t shift while you’re working.

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Common Mistakes to Avoid ❌

• Sizing foam to finished thickness – always measure to the cover border, then let the Dacron add loft.
• Skipping adhesive – unglued wadding moves, bunches, and looks messy.
• Over-wrapping – too many layers will make the cover impossible to zip.
• Ignoring corners – bulky untrimmed corners ruin the shape.
• Under-ordering Dacron – headboards and large panels need extra to wrap right around.

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Where to Buy Upholstery Wadding 🛒

At Foam4U we stock polyester wadding in 27″, 36″ and 54″ widths. Available by the metre, in 5-metre multiples, or full rolls. Perfect for:

• Sofas & armchairs 🛋️
• Campervan & caravan cushions 🚐
• Boat cushions & mattresses ⛵
• Window seats & benches 🪑
• Upholstered headboards & panels 🛏️

👉 Shop here: Polyester Wadding (Dacron)

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Final Thoughts 💭

Wrapping foam cushions with polyester wadding is one of those small steps that makes a massive difference. It adds loft, improves comfort, protects covers, and gives your project that professional upholsterer’s finish.

Just remember:

• Match the cover border with your foam.
• Add the right weight of Dacron on top (10½oz suits most cushions).
• Always glue the wadding to the foam.

Follow those rules, and your cushions will fit perfectly, feel better, and last longer.

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When mobility gets tougher, the right cushion or support can make all the difference. From wheelchair cushions to booster seats and even bed extenders, people ask a lot of questions about disability cushions before buying. Let’s tackle the most common ones.

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🦽 What’s the best cushion for a wheelchair?

High-density or memory foam wheelchair cushions distribute weight evenly and reduce pressure sores. They’re the go-to for long-term comfort.
👉 See our wheelchair cushions cut to size.

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📏 How thick should a booster cushion be?

Booster cushions are usually 7–12cm thick, depending on the chair and user’s height. The aim is to make sitting and standing easier without throwing posture off.
👉 Browse our booster cushions cut to size.

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🌟 Do pressure relief cushions really work?

Yes. They ease strain on hips and legs, improve circulation, and make long periods of sitting far more comfortable — especially for elderly users or post-surgery recovery.
👉 Explore our pressure relief cushions.

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🧘 What’s the best cushion for posture and back support?

Foam wedges, lumbar rolls, and cut-to-size back cushions improve alignment and reduce strain. Good posture = less pain.
👉 Shop our posture cushions.

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🛏 Can I make my bed longer or wider without replacing it?

Yes — a bed extender lets you widen or lengthen your mattress in seconds. Perfect for:

• Adding length for taller sleepers
• Joining two singles into a double
• Creating more room without buying a whole new mattress

👉 Order your foam bed extender cut to size.

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❓ Other Common Questions

Can you get disability cushions made to measure?
Yes, we cut every cushion to your exact size and shape.

How often should cushions be replaced?
Every 2–3 years, or sooner if the foam goes flat.

Are memory foam cushions worth it?
Absolutely — they offer superior support, especially for long-term use.

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🏠 Final Word

Comfort, posture, and independence all start with the right support. Whether it’s a wheelchair cushion, booster seat, pressure relief pad, or a mattress extender, the right foam product makes daily life easier.

👉 Explore our full range of Disability Products →

📏 Why Accurate Measuring Matters (what happens if your measurements are wrong?)

A perfect fit starts with accurate measurements. Even a few millimetres off can make the difference between a cushion that sits neatly in its cover and one that bulges, wrinkles, or looks baggy.

Good measuring means:

• Snug fit with no gaps or bunching.
• Even wear and longer foam life.
• A better-looking, more comfortable seat.

Not a fan of measuring? Our Cushion Refill Service lets you send us your covers — we’ll measure, cut, and fit the foam for you.

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🛠 What You’ll Need (what’s the best way to get accurate measurements?)

• A rigid tape measure (fabric ones stretch).
• A flat work surface.
• Pen and paper (or our downloadable Measuring Sheet PDF).
• Your cushion cover or old foam insert.

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1️⃣ Measuring from the Cushion Cover (should I measure the cover or the old foam?)

1. Remove the old insert completely.
2. Lay the cover flat on a table — no stretching.
3. Measure seam-to-seam for width and depth.
4. Measure thickness at the highest point of the side panel (border).

💡 Important: The border is not always the finished foam thickness. See “The Border Rule” below.

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🔍 The Border Rule – Foam vs Dacron (how much thickness does Dacron add?)

If you’re replacing old foam, the border measurement is a guide — but you’ve got choices.

When the border is 10 cm (4″) or more:

• Foam matches border + 12 oz Dacron – Looks rounded and plump, but with less foam volume so support is softer.
• Slightly deeper foam, no Dacron – 12.5 cm (5″) foam gives more volume and firmer support, but with a squarer finish.

💡 Borders under 10 cm usually work better with the Dacron method for a smooth fit.

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⚠ Swapping Fibre or Feather for Foam (why doesn’t foam fit the same as feather cushions?)

Feather and fibre cushions squash into spaces — foam won’t.
If your cover width is 30″ on a two-seater, you’d expect a 60″ arm gap. In reality, it might be less. Fine for soft fills, but foam needs the full space.
If in doubt, contact us for advice before ordering.

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2️⃣ Measuring from the Old Foam Insert (can I just copy the old insert size?)

1. Place foam on a flat surface — no compression.
2. Measure the widest width and depth.
3. Add a couple of mm if edges have pulled in over time.

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3️⃣ Measuring Irregular Shapes (how do you measure domed or curved cushions?)

• Start with the widest width and deepest depth.
• Break the shape into smaller sections and measure each.
• For curves/angles, make a paper template for precision.
• Compare to our Foam Shapes Guide before ordering.

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4️⃣ Allowances for a Snug Fit (should foam be cut bigger or smaller than the cover?)

• Foam: Subtract 5 mm from width and depth for easier fitting.
• Fibre or Feather: Use exact measurements.

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🚫 Common Measuring Mistakes (what causes most wrong cushion orders?)

• Guessing without a tape measure.
• Measuring with the cushion still in the cover.
• Ignoring warped shapes.
• Forgetting to measure thickness accurately.

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✅ Ready to Order? (how to order your new cushions quickly and correctly)

• Enter your sizes in our Foam Cut to Size Configurator.
• Choose your foam grade, firmness, and extras like Dacron wrap or stockinette.
• Or send us your covers for the hassle-free Cushion Refill Service.