How to Wrap Foam Cushions with Polyester Wadding

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.

Why Wrap Foam Cushions in Polyester Wadding? 🤔

✅ 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.

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.

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.

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.

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.

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.

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)

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: