At Aerofoam Ltd, we operate as a principal UK B2B cushion manufacturer, delivering tailored cushion cores, interiors and finished cushion assemblies for furniture manufacturers, upholsterers, bespoke furniture makers, contract seating manufacturers, interior specialists, commercial furniture suppliers and healthcare product suppliers.
Operating from our Stanmore manufacturing plant, we combine computer-controlled CNC foam profiling with traditional cushion-filling craftsmanship. Whether supplying high-volume seating inserts for contract furniture ranges or hand-crafted hybrid cushions for bespoke upholstery, every cushion is manufactured to exact specifications, cover dimensions or customer templates.
Our bespoke cushion manufacturing is backed by our principal supporting industry credentials: active memberships in the British Furniture Association (BFA), supporting UK furniture manufacturing excellence, and Commercial Interiors UK, connecting our cushion solutions with commercial contract specifiers nationwide.
Comprehensive Cushion Constructions & Formats
We manufacture all primary commercial and residential cushion formats, including:
- Foam Seat & Back Cushions: Precision CNC-cut CMHR polyether and High Resilience (HR) foam cores engineered for firm support and clean tailing lines.
- Hollow-Fibre Cushions: High-loft carded polyester fibre interiors supplying soft, breathable volume for back cushions and casual seating.
- Feather & Down Cushions: Pure duck feather and feather-and-down blends encased in down-proof cambric ticking for traditional luxury feel.
- Foam Cushions with Fibre Wraps: Resilient foam cores wrapped in thermally bonded polyester (Dacron) wadding to plump covers and soften edges.
- Foam Cushions with Feather-and-Down Wraps: Supportive foam cores enclosed in partitioned feather envelopes for luxury sink-in comfort with structural shape recovery.
- Scatter Cushion Interiors: Custom-sized feather, fibre, or foam-chip interiors for accent and decorative cushions.
- Bench & Banquette Seating Cushions: Continuous straight or angled seating pads engineered for hospitality booths, dining banquettes and window seats.
- Contract Seating Cushions: Fire-retardant (BS 5852 Crib 5) high-traffic cushion inserts for hotel lounges, restaurants and public venues.
- Replacement Cushion Interiors: Precision trade-replacement cores cut to refresh existing upholstery covers exactly.
- Bespoke Shapes from Drawings or Templates: Manufactured from physical patterns, digital CAD files, or detailed customer drawings.
Cushion Construction Performance & Technical Comparison
Selecting the optimal cushion construction requires balancing support, softness, visual appearance, maintenance requirements and intended application. Below is an objective technical guide to our principal cushion filling types:
| Construction Type | Relative Support | Softness & Feel | Appearance | Maintenance | Suitable Application |
|---|---|---|---|---|---|
| Foam-Only Cores | High / Firm | Tailored & Supportive | Crisp, structured, unwrinkled lines | Low (No plumping required) | Contract seating, commercial benches, office chairs, crisp seat bases |
| Fibre-Filled | Medium / Soft | Soft, casual, springy | Plump, rounded, relaxed look | Moderate (Regular plumping needed) | Domestic back cushions, casual armchairs, scatter cushions |
| Feather-and-Down | Soft / Moldable | Ultra-soft luxury "sink-in" | Traditional relaxed, rumpled elegance | High (Daily plumping required) | High-end residential accent seating, luxury back cushions |
| Foam & Fibre Combination | Balanced High-Medium | Supportive core with soft initial surface | Smooth, domed, tailored covers | Low to Moderate (Minimal maintenance) | Domestic sofa seat cushions, contract soft seating, bench pads |
| Foam & Feather/Down Combination | High Core + Soft Surface | Luxurious sink-in without bottoming out | Rich, plush, semi-structured appearance | Moderate (Periodic plumping of outer envelope) | Executive lounge chairs, luxury sofa seat cushions, boutique hotel seating |
Detailed Construction Characteristics
1. Foam-Only Cushions
Engineered from single or multi-density CMHR polyether or High Resilience (HR) polyurethane foam. Provides immediate support and complete shape recovery. Ideal for applications requiring crisp tailored tailoring, heavy contract use, or low-maintenance requirements where users do not plump seating.
2. Fibre-Filled Cushions
Manufactured using carded hollow conjugated polyester fibres blown into inner cotton casing pockets. Offers a softer, more casual feel than solid foam. Best suited for back cushions where body weight support is minimal.
3. Feather-and-Down Cushions
Filled with washed, sterilized duck feather and down blends encased in heavy down-proof cotton ticking. Delivers unmatched moldable softness and a luxurious traditional aesthetic, suitable for premium upholstery ranges where regular care is accepted.
4. Foam and Fibre Combinations (Fibre-Wrapped Cores)
Our most popular trade specification. A high-density foam core supplies structural integrity and support, while an outer layer of thermally bonded polyester (Dacron) wadding is adhesive-bonded to top and bottom faces. Wrapped in a stockinette sleeve, this construction plumps cover corners, prevents fabric friction and removes harsh foam edges.
5. Foam and Feather-and-Down Combinations (Feather-Wrapped Cores)
A premium hybrid solution featuring a resilient central foam core insert contained within a jacket of channelled, down-proof feather envelope pockets. The central foam core prevents the cushion from compressing flat or bottoming out under weight, while the outer feather envelope provides luxurious initial softness.
Manufacturing from Templates & Drawings
We accommodate all trade workflow preferences to guarantee precise fitment inside upholstered frames:
- Paper & Cardboard Patterns: Send us physical template cut-outs for complex radii, L-shapes, or vintage frame restorations.
- CAD & Technical Drawings: Digital DXF/DWG file processing for direct multi-axis CNC profiling.
- Cover Dimensions: Manufacturing to seam-to-seam cover measurements with accurate dome allowances.
- Prototype & Sample Testing: Small-batch sampling for furniture design testing before volume production.
Liners, Casings & Outer Materials
To ensure technical clarity across all trade specifications, Aerofoam clearly distinguishes between the three distinct components of an upholstered cushion assembly:
1. Cushion Filling
The internal filling or core construction (e.g., CMHR foam, High Resilience foam, carded hollow fibre, or feather & down blends) supplying structural support, resilience and shape recovery.
2. Internal Liner or Casing
The protective inner lining or casing (e.g., knitted stockinette, polyester wrap, or down-proof cotton cambric casing) that encloses the filling and facilitates smooth cover fitting.
3. Decorative Cover
The finished decorative fabric or leather outer cover fitted by upholsterers or manufacturers. Aerofoam manufactures internal cushion cores, liners and casings; finished decorative outer covers are supplied by upholsterers unless separately confirmed.
Material Specifications & Client Approval Items
Aerofoam manufactures cushion interiors to exact customer specifications. The following material options are confirmed per client order:
- Liners & Inner Casings: Selection of stockinette, spunbond, or woven inner linings based on cushion type.
- Feather-Proof & Fibre-Proof Fabrics: Down-proof cotton cambric and high-density fibre-proof casings.
- Fire-Retardant Casing Options: BS 5852 compliant fire-retardant inner casing materials where required for contract specs.
- Customer-Supplied Materials: Processing policy for customer-provided ticking or casing fabrics.
- Finished Outer Covers & Closures: Supply of finished decorative outer covers, zips, or removable outer casings is subject to specific client agreement.
