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Aerofoam Ltd Bespoke Cushion Manufacturing

At Aerofoam Ltd, we are experts in bespoke cushion manufacturing, delivering tailored comfort solutions for furniture makers, interior designers and the hospitality sector. We understand that a cushion is not just about aesthetics; it's about lasting comfort, support and durability.

From luxurious deep seating for luxury sofas to firm, supportive padding for dining chairs or commercial banquettes, we offer a vast range of high-quality foam grades. We can cut your cushions to any shape or size, complete with Dacron wrapping and stockinette for a professional finish.

Our Custom Cushion Services

  • Sofa & Chair Replacement Cushions

    Revitalize sagging furniture with high-density, resilient foam cut to your existing cover's exact dimensions.

  • Window Seats & Bench Pads

    Custom-shaped cushions to fit alcoves, bay windows, or outdoor dining benches perfectly.

  • Marine & Caravan Seating

    Specialized durable and specialized foams suitable for the unique demands of boats and mobile homes.

  • Commercial Banquette Seating

    High-traffic, fire-retardant (CMHR) foam solutions for restaurants, bars and hotels.

  • Dacron & Stockinette Wrapping

    Adding a layer of polyester wadding (Dacron) gives cushions a softer, rounded look, while stockinette makes fitting covers effortless.

Why Choose Aerofoam?

  • Extensive range of foam densities (soft, medium, hard)
  • Fully compliant with UK fire safety regulations
  • Precision cutting for complex shapes (L-shape, T-shape, curved)
  • Fast turnaround times for trade and commercial orders
  • Expert advice on the best foam grade for your specific application

Need high-quality, bespoke cushions for your next project?
Contact our team today to discuss your requirements and get a tailored quote.

Get Started

Request a Quote or Sample

Tell us your requirements and our team will respond within 24–48 hours with a tailored solution.

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FAQs

Frequently Asked Questions

How do I measure for a bespoke replacement cushion?

Always measure your existing cushion covers, not the old foam inside (which has likely compressed over time). Measure edge-to-edge from the seams, noting the maximum width, depth and the depth of the border (thickness).

What foam density is best for sofa seating?

For seat cushions, we generally recommend a high-density, firm foam (like Blue or Reflex foam) as it offers the best support and longevity. For back cushions, a softer grade is preferable for comfort.

What is Dacron wrapping and do I need it?

Dacron is a polyester wadding glued to the top and bottom of the foam. It softens the hard edges of the foam, plumps up the cushion cover to remove wrinkles and provides a luxurious domed look. We highly recommend it for domestic seating.

Do you supply cushions for outdoor furniture?

Yes, we can manufacture bespoke cushions using specialist reticulated outdoor foam. This foam is designed to let water drain through it rapidly, preventing mould and allowing the cushion to dry quickly after rain.

Can you make cushions in unusual shapes?

Yes. Whether you need L-shapes, T-shapes, curved window seats, or circular cushions, our advanced CNC cutting technology allows us to create perfectly accurate shapes to match your templates.