The Boxing Panel

The measurement of the boxing panel of a seat or back cushion is crucial in determining the thickness of foam that we will use.  Our approach is to use a thickness of foam that is the same dimension as the height of the boxing, i.e. 3" boxing on the cover gets a 3" thick foam core.  The foam is the firmest part of the cushion and we want the edge of the foam to line up with the seams of the cover and hold them straight.  The material that is wrapped around the foam, whether it be polyester, down/feather or wool, just adds to the total thickness of the cushion, which we call the "crown".

Poly / Down Seat Cushion

By Poly / Down we mean a seat cushion with a foam core that is inside a down/feather filled envelope (or jacket).  Old timers refer to polyurethane foam as "poly" and "down" refers to a down and feather blend.  Some common blends for cushions are 10% down/90% feather, 25% down/75% feather (pictured below) and 50% down/50% feather.

We used the original cover (at the top left) as a pattern for cutting the foam.
The finished boxing on the cover is 4" so we used a 4" thick High Resiliency
foam core.  The thickness of the foam is the same as the finished boxing
so that the edges of the foam to line up with the seams of
the cover to hold them straight and tight.

Our down & feather filled jacket is cut a little larger than the finished size
of the cover.  It also includes a crown allowance which allows finished
cushion to be very full and round.  We also sew partitions into the ticking.
This keeps the down/feather in separate channels which helps
the customer to maintain the cushion.  It also allows for the high
crown that is indicative of this type of construction.

A zipper at the back of the cushion makes it easy to access the foam core
for maintenance.

The foam core is inserted into the envelope.

Zipped up.

This cushion has a crown of about 8".  The foam is 4" thick.

The finished cushion ready to be covered.