How Are the Upholstery Foam Cut and Shaped For Curved Projects?

Cutting and shaping the upholstery foam for curved objects needs specialized tools and skills. The professionals own the necessities, hence one can easily rely on them.

Cushions, footrests, bumpers and bucket seats have to be upholstered with properly shaped foam, so the professional upholsterers are much more careful while shaping the upholstery foam. Along with upholstering new objects, when the upholstery is fixed on a curved sofa using foam is indeed highly rewarding. Fabric tension for shaping softer foam determines the novices, but there is a high chance of foam becoming uneven curves, hard edges or puckered fabric.

Here is how the professionals work on upholstery projects at their workshops in Sydney and cut and shape the curved objects.

1. Measuring the Foam

Measuring the shape of the upholstery objects is the start.

a. For foam replacement – The upholstery professionals get the correct size by measuring the fabric casing from the seams’ inside, and not of the existing foam. They measure the existing foam only when the piece is relatively new. The reason is the foam is likely to shrink over time on being used

b. For Working On New Upholstery Creation – Here, the upholstery object patterns' measurements are taken. In case, the pattern is not exiting, then the project is broken down into easily manageable shapes. They measure twice from each shapes' widest parts.

For the continuous edges, they measure and order a single foam for fitting the complete perimeter. They do not sew or stitch the foam together since it creates inconsistencies at the joining point of the edges that create divots.

They connect two foam pieces of the same material, brand, compression and density. By using foam glue, they stick them together before giving them the shape. Even now, the foams are not sewed or stapled together due to inconsistencies.

2. Drawing the Marking On Foam

Foam comes in sheets or rectangular blocks. Cutting the foam to the approximate size, the professional upholsters start marking where the foam will be cut. They mark the foam's outside edges and its highest point. They measure the fabric's correct size. Since the foam will be compressing over time, so they do not undercut.

The edge marking is connected with the deepest point with a marker. They use a string piece attached to a pen for a consistent curve. By holding the string at the curve's centre, they draw from one corner to the other.

3. Cutting Large Shapes of Foam

By using specialized foam cutters or else the power tools like electric foam saw, the professionals can quickly cut the upholstery foam. For the projects with high curvature, they start by getting rid of the large surface area at once. By marking the straight line meeting the highest point of the curve, they remove most volume right in one cut.

To make more substantial cuts, they use an electric foam saw, razor blade, bread knife or scissors.

4. Cutting the Final Foam Curve

After the larger surface area is removed, then they focus on creating a consistent and smoothed edge. Through these cut ends, they can create a consistent curve along the total edge. They refrain from frequent cuttings and watch over the project for ensuring a consistent edge.

The discussed process is totally similar to firm and soft foams, nevertheless, they take care of a few considerations.

i. Firm Foam – By sanding the upholstery foam using a fine grater or coarse sandpaper, it can be smoothed. The gradual breakdown produces a smooth and precise finish.

ii. Soft Foam – By using a sharp blade, the upholsterers carefully work so they can avoid the holes or rips in the foam likely to impact its integrity.

At the time of cutting the foam, they apply the least pressure so the foam is not compressed and ended up with a misshaped outcome. By 'scoring' the foam repeatedly, it can be achieved, till it is cut all the way through.

Are you planning to get a new customized cushion? Then take the custom made ones by the upholsterers. They know the exact steps to tailor it as per your needs. Convey your design choice and thickness, so they can get the foam of exact thickness for upholstering the cushion. Remember, each specification has a role to play in measurements. So, you have to be accurate.