Switching out the old foam cushions for new ones always makes a difference. The job pictured above was for a customer’s 20 year old sofa. The cushions were flat, the covers loose and they were too soft to sit on comfortably. Since he has teenage twins who love playing video games on this the primary sofa in the house, he needed to firm the seats up. We measured the covers and as you can see from the picture, they were designed to contain a much thicker cushion than what they had become. We fit the cushions with a firm High Resiliency foam that was wrapped with bonded polyester. As you can see in these photos, the difference is dramatic.
By the way, these cushions were High Resiliecy (HR ) foam, density 2.5lb, ILD 45, cut 24” x 24” x 5 1/2” thick with a bonded polyester wrap.
Send us an email if you need help with your project.
Thursday, December 15, 2011
Monday, November 7, 2011
Tuesday, November 1, 2011
|A zipper at the back of the cushion makes it easy to access the foam core|
|The foam core is inserted into the envelope.|
|This cushion has a crown of about 8". The foam is 4" thick.|
|The finished cushion ready to be covered.|
Monday, October 17, 2011
|Left - Boxed Pillow|
Right - Cut-Out Pillow
Friday, October 14, 2011
Before you order your pillow forms, check your cover or with your sewing workroom to see if you covers are cut with a Crown Allowance or are Straight Cut. We make our pillows to order and can accommodate either approach. Unless we are told otherwise, all of our pillows are cut with a crown allowance (or bow).
|Crown Allowance: When a pillow is cut this way is filled, the sides tend to be straighter.|
|Straight Cut: When a pillow is cut this way the sides pull in when filled and|
the corners become sharper, what we call "dog ears".
Friday, October 7, 2011
|A stack of random foam?|
|Sort by shape.|
|Glue pieces together|
|Wrap with polyester, line with muslin.|
This project required a profile with a curve on the top front of the cushion with 90 degree angles on the back and bottom. We broke down the finished shape into easy to cut pieces that we later assembled.
Monday, September 19, 2011
|This bench cushion has a long cut out in the middle. We first mark the foam and then cut with the foam saw.|
|The polyester is cut to the same shape as the foam. On this cushion, it sits on the top and bottom of the foam core only. We left the edges free of polyester because we want the cover to have a flat front.|
Thursday, September 1, 2011
Thursday, August 25, 2011
Monday, August 22, 2011
Tuesday, August 2, 2011
Friday, July 29, 2011
Wednesday, July 27, 2011
Wednesday, July 20, 2011
Friday, July 15, 2011
Tuesday, June 28, 2011
High Density foam w/ Dacron 91 wrap, muslin tick
With use, all foam gets softer and all polyester flattens. High Density foam, which is available in five levels of firmness, resists softening the best. The best option for wrapping the foam is with Dacron 91 made by DuPont. It's springy fiber stays fluffy and resists flattening best out of all the polyester battings. To hold everything in place we make a muslin lined jacket out of the Dacron 91 and the foam core fits inside. The jacket is closed with a zipper at the back.
High Density Foam w/ bonded wrap, glued, no lining
Bonded polyester is the easiest, quickest batting to work with. It is cut to size and glued to the surface of the foam. Bonded polyester has the least amount of resiliency and will flatten the quickest. We have 4 different weights (thicknesses) of bonded polyester to choose from: 1/2 oz. , 3/4 oz., 1 oz. & 1 1/4 oz.
Monday, June 20, 2011
Wednesday, June 8, 2011
We then wrapped the foam with Dacron 91 batting (very resilient to resist denting) and fit the form into a muslin tick. This will allow the customer to easily remove the outer cover. In these pictures, the new cushion sits beside its mate already fitted into the finished cover.