The Making of a Bench Cushion

This bench cushion has a long cut out in the middle.  We first mark the foam and then cut with the foam saw.

 All foam is cut with perfectly flat sides.  It is difficult to get a cover to be tight on a flat surface, so we wrap the foam with either a polyester or a down/feather envelope to help tighten the top and bottom panels of the cover.  For this cushion we are gluing the bonded polyester to the foam.

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. 

The foam in these photos is 2 1/2" thick and will be covered with a cover that has a finished boxing panel of 2 1/2" too.  The edges of the foam will hold the piping on the cover straight while the polyester will push up against the top and bottom panels, creating a crown and making the cover look tight and fit.

Recipe for Wedge Shaped Foam

Start with 1 block of foam.

Slice at desired angle.

Separate!

The angled cut always yields 2 wedges.

Note: If you need only 1 wedge shape, we cut the wedge from a block that is half as wide as your finished product. Then we glue the cut pieces side to side to create a shape that is the full width. For example, if we need one wedge that is 36" wide, we cut the shapes from a block that is 18" wide and then glue the two 18" pieces together to make 36".