Home / Our Process
Cut where it's made, not warehoused and marked up
Foam Tailor runs out of our own polyurethane foam manufacturing site in Alfreton, Derbyshire. Orders are cut from manufactured stock on-site, rather than bought in from a third party and resold — so density, firmness and batch quality are known, not assumed.
Source & select
Foam is drawn from manufactured stock at the correct density and grade for the job, not bought in pre-cut.
Precision cut
CNC cutting technology follows your exact spec — straight edges, curves, notches and angled panels alike.
Finish & dispatch
Stockinette or fibre wrap added if specified, checked against the order, and shipped — most orders within 1–3 business days.
Choosing the right foam
Not sure what to spec? This is a general guide. If your project has particular requirements, such as a fire rating, mention it when you send your spec list.
| Firmness | Best for | Density (approx.) |
|---|---|---|
| Soft | Scatter cushions and backrests | 25 kg/m³ |
| Medium | Everyday seating and sofa cushions | 30–35 kg/m³ |
| Firm | High-use and contract seating | 40 kg/m³ + |
| Order | Dispatched in |
|---|---|
| Ready-cut sheets and simple shapes | 1–3 working days |
| Custom outlines and batch orders | Confirmed with your order |
Common questions
What shapes can foam be cut into?
Thirty-three standard shapes, from rectangles, curved L, T and U-shapes and dining chair seats to bay window seats, boat V-berths, wheel-arch cut-outs, arched headboards, bull-nose and chamfered seats, kneelers, wedges and bolsters. You can also draw your own outline on a grid and get an instant price, plus fully custom outlines supplied as a sketch, template or set of measurements.
How is bespoke foam priced?
By volume (thickness × footprint area) plus any add-ons. The spec builder on the home page shows the exact price, VAT included, as soon as you enter your measurements. Ready-cut sheets have fixed prices with delivery included.
How long does an order take?
Ready-cut sheets and simple shapes typically ship within 1–3 working days. Lead times for complex custom outlines or larger batch orders are confirmed with your order.
Is Foam Tailor a manufacturer or a reseller?
Foam Tailor cuts to order at our own polyurethane foam manufacturing site in Alfreton, Derbyshire, rather than reselling foam bought in from a third party.
Ready to spec your project?
Build a shape and see the exact price straight away.