Curving Wedges

A recent project called for several wedge back cushions to follow the gentle curve of a built in bench. 

Recycling Foam

It's time to recycle all of the old cushion foam and off cuts.  These bags contain cut down foam that will go to the foam plant to be shredded, re-bonded, and sliced to make carpet pad.  

Slim, Sculpted Floor Seating

We were recently presented with some very pretty round covers with a knife edge (knife edge is two pieces of fabric sewn together, like a bed pillow) and asked to make very firm inserts so that the client could use them as floor cushions.  Unlike a sofa cushion which has a boxing panel sewn in which allows for the blockiness of a foam core, a knife edge seam doesn't fit a foam insert.  Our solution was to shave down the edge of the foam to make it sharp which will neatly fit with the cover's seam.  We then wrapped the foam with polyester which softens further the shape of the foam and takes the slack out of the fabric, tightening it and removing wrinkles.  Once the inserts are installed in the covers, a full, firm insert is ready for the home.

Die Cut Foam

We just provided a client with 7,000 pieces of die cut foam to be used in packaging their liquid filled flasks for shipping.  They needed a charcoal gray foam that would have 12 round holes that went all the way through the foam.  We had a sample made for approval, made a slight adjustment on the diameter of the hole and put the job into production.  The pieces were delivered and the product was received in time for Holiday shipping.

A phone call leads to a sketch.  Close but not quite right.

A 3-D illustration helps everyone to visualize the end product. 

We cut one sample for approval.  The diameter of the holes was a little too small.

The final product held the snugly fit the flasks.

Fun with Foam Shapes

We recently cut this set of foam triangles.  Don't know how they are being used, but we like to line them up on the table in an obvious formation.

Cushion Works turns 35!

After the Holiday Break Tang Welcomes Us Back to Work