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Custom Shape Foam Cut To Size

Custom Shape Foam Cut To Size

Choose between a standard foam make up or bonded (multi foam)
Please add the ratio of foams e.g. 60% Memory Foam / 40% Premium blue if selecting "Memory Foam Mixed With FS Premium 39H Blue Firm"
The Budget Blue Foam (Grade 33) is our most used high-density foam grade. It is a firm foam, widely used for dining pads, upholstery repairs, garden seating, window seats and caravan seating. For high-use items, please choose the Premium Blue foam instead.

Specification/Data Information
  • Colour - Blue
  • Density (Kg/m3) (1) 34-37
  • Hardness (N) (2) 110-140
  • Tensile (ka-min) (4) 50
  • Elongation (% min) (4) 90
    • The "36 Budget Beige Foam" is perfect for sofa cushions, seat pads, and campervans. Its optimal density, hardness, and durability ensure comfortable seating and long-lasting support. Whether you need cushioning for your living room, dining chairs, don-the-go sleeping arrangements, this foam grade has you covered.

    Specification/Data Information
  • Colour - Beige/Pink
  • Density (Kg/m3) (1) 34-37
  • Hardness (N) (2) 110-140
  • Tensile (kPa-min) (4) 50
  • Elongation (% min) (4) 90
    • Our Premium Blue Firm Foam (Grade 39) is a high-density foam, perfect for sofa seats if you are looking for a very firm cushion. It is also suitable for many other applications, including upholstery repairs, boat seating, caravan and campervan seating, window seats, dining pads and much more. Our premium blue 39h foam can be supplied in either pale pastel or a ocean blue colour. Both have the exact same density’s and properties to one another. Colour is purely dependant on the supplier it is provided from.

    Specification/Data Information
  • Colour - Blue
  • Density (Kg/m3) (1) 38-40
  • Hardness (N) (2) 180-220
  • Tensile (kPa-min) (4) 50
  • Elongation (% min) (4) 90
  • Comp set (% max) (5) 8
    • We are experiencing foam shortages on certain foam grades (this grade is effected, Lead times are up to 4 week) sorry for any inconvenience. Find out why here

    Our Luxury Reflex Grey Foam (Grade 40) is a premium high-density foam with a high resistance and a bounce-back touch. It’s medium feel foam, ideal for sofa seat replacements providing comfort and resistance.
    Our 6lb Recon Foam is a very firm grade, used for hard-wearing seats. It’s ideal for bar seating and stools, church kneelers, gym mats and other hard-wearing commercial furniture.
    Our Memory Foam is a high quality foam, used to add extra comfort and support to any mattress. It can also be used for mattress toppers, pillows, wheelchair cushions and much more.

    Specification/Data Information
  • Colour - Yellow/White
  • Density (Kg/m3) (1) 38-42
  • Hardness (N) (2) 60-90
  • Tensile (kPa-min) (4) 50
  • Elongation (% min) (4) 160
  • Recovery Rate 3-second
    • Our Luxury Reflex Pink Foam is a premium high-density soft foam. This foam grade is a suitable choice for the replacement of sofa back cushions (which are fibre filled or foam filled).

    Specification/Data Information
  • Colour - Orange
  • Density (Kg/m3) (1) 38-40
  • Hardness (N) (2) 100-140
  • Tensile (kPa-min) (4) 50
  • Elongation (% min) (4) 90
    • Our White Foam is a budget craft foam, that can be used for crafts projects, upholstery repairs, headboards and much more. Not suitable for sitting on!

    Specification/Data Information
  • Colour - White
  • Density (Kg/m3) (1) 24-26
  • Hardness (N) (2) 50-70
  • Tensile (kPa-min) (4) 50
  • Elongation (% min) (4) 150
    • Luxury Reflex Grey Foam is a high-quality foam that offers excellent bounce and resilience. It is specifically designed for sofa seating applications, making it a perfect choice for those looking for a comfortable and supportive seating experience. With its grey color and luxurious feel, it is our most popular foam grade and is sure to elevate the look and feel of any seating area. Whether you're looking to upgrade your living room or design a new seating area for your office, Luxury Reflex Grey Foam is the perfect choice.

    Specification/Data Information
  • Colour - Grey
  • Density (Kg/m3) (1) 40-42
  • Hardness (N) (2) 130-160
  • Tensile (kPa-min) (4) 100
  • Elongation (% min) (4) 250

    • Pick your extras

    Extras are a great way to add to your foam
    You should always fit stockinette to your order. In simple terms Stockinette makes it much easier to slide the foam in an out of your cover and will not only reduce creasing of fabric but prevent premature wear to both the foam and the cover - ensuring your cushions retain their shape better and last longer. Read More About Stockinette (Please Note Maximum Width for Stockinette = 135cm)
    Helps extend the lifespan of your foam cushions.
    Please note there is a minimum order of £25 on all made to measure Foam
    Grand total
    Category:
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    Important Ordering Information

    ⚠️ PLEASE ONLY SELECT THIS PRODUCT IF YOU ARE SENDING IN EXISTING COVERS, A HAND-DRAWN TEMPLATE, A CLEAR SKETCH, OR A DXF FILE REPLICATING THE SHAPE YOU WISH TO CREATE.

    For irregular cushions, bay window seating, or bespoke furniture projects, we can only cut foam accurately when we receive either:

    • Your existing cushion covers (which we copy exactly)

    • A carefully prepared cut-out template

    • A clear hand-drawn sketch with measurements

    • A digital DXF file

    This ensures the finished foam matches your design with precision.

    How to Provide Your Template or File

    1. Measure First – Always measure to the longest point on width × length × depth.

    2. Prepare Your File or Template –

      • Physical templates: use paper, card, or fabric.

      • Sketches: must be neat, clear, and labelled with exact measurements.

      • DXF files: email to our team once your order is placed.

    3. Include Your Details – Always provide your name, order number, and contact details.

    4. Sending Physical Templates or Covers – Use tracked postage to ensure safe delivery.

    5. Postal Address:

    📍 Intercounty Supplies
    County House
    Manby
    Louth
    LN11 8UT

    Why Choose Intercounty Supplies?

    • Trusted Since 1990 – Over 30 years in the upholstery trade.

    • One of the UK’s Biggest Foam Converters – Handling one-off jobs through to large trade supply.

    • CNC Profiling – Advanced cutting technology for irregular and complex shapes.

    • Nationwide Delivery – Backed by our own fleet of 5 artic trucks and 15 Luton vans.

    • Flexible Ordering – Covers, templates, sketches, or DXF files all accepted.

    Order Today

    Get precision foam for even the most complex shapes with Custom Shape Foam Cut to Size from Intercounty Supplies.

    👉 Order now and send us your covers, template, sketch, or DXF file to get started.

    💬 Unsure which option is best for your project? Contact us here – our team will guide you through the process.

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