Different Types of Polyester Wraps around a Foam Core

The most basic cushion construction is a foam core with a polyester wrap. The foam provides the support and lines up with the seams in the depth, width and boxing of the cushion. Foam is cut with a straight blade and is perfectly flat on all sides. It is difficult to have a cover be tight and wrinkle-free on a flat surface. To aid in the fit and to soften the appearance of the foam, we wrap it with polyester (and down/feather, but that is for another entry). The polyester pushes out against the cover which tightens it and eliminates wrinkles. Below is a discussion of two types of polyester wrap.

High Density foam w/ Dacron 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. 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 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 1/4 oz.