Precision Cutting
CNC Foam Cutting
Precision CNC cutting and fabrication for shaped, technical and repeat-production foam components.
Explore CNC CuttingCMS Foam Services
Bespoke Foam Solutions
We manufacture bespoke foam products tailored to your exact requirements — from precision cut-to-size foam and custom inserts to bonded and laminated foam constructions. Whether you need a one-off prototype or repeat production, we deliver consistent, high-quality results.
Chat with our team
Trade, OEM, bespoke and volume production enquiries welcome.
What We Offer
- Cut to sizeAny shape or dimension
- Foam insertsProtective & presentation
- LaminationBonded multi-layer foam
- Foam typesPU, memory, recon & more
- SupportTechnical guidance available
Send drawings, dimensions or a brief — we’ll help you get to the right solution quickly.
See It In Action
See how Foam Studio works
Watch a quick walkthrough of choosing your shape,
dimensions, foam and finish.
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Watch Demo
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See It In Action
See how Foam Studio works
Watch a quick walkthrough of choosing your shape, dimensions, foam and finish.
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Bespoke foam, built around your requirement
Every application is different. That’s why we manufacture foam components to your exact specification — whether that’s simple cut panels, intricate packaging inserts or layered constructions combining multiple foam grades.
Our team works with you to understand the use case and recommend the most suitable material, density and construction method.
What we manufacture
- Cut to size foam sheets and blocks
- CNC-cut foam components and shapes
- Custom foam packaging inserts
- Bonded and laminated foam products
- Seating, bedding and industrial foam parts
Industries we support
- Furniture and upholstery manufacturing
- Medical and healthcare equipment
- Protective packaging and logistics
- Automotive and engineering
- Retail display and presentation
Manufacturing Capabilities
From Cutting to Finished Components
Our in-house conversion services allow us to cut, shape, insert and laminate foam for one-off projects and repeat production.
Protective Packaging
Custom Foam Inserts
Bespoke foam inserts designed to present, protect and secure equipment, products and components.
Discuss Your Insert
Bonding & Layering
Foam Lamination
Multiple foam layers bonded together to create specific comfort, support and performance characteristics.
Create a Laminated CushionOur core foam services
Cut to size foam
Precision cutting to any dimension, from single pieces to batch production. Suitable for upholstery, mattresses, seating and industrial use.
Foam inserts
Custom-designed inserts to protect, present and secure products during transport or display.
Foam lamination
Bonding multiple foam layers together to achieve specific comfort, density or structural performance.
Material selection
Guidance on choosing the correct foam grade, density and construction for your application.
Typical applications
Bar Seating
Custom laminated foam seating engineered for long-lasting comfort and support in bars, pubs and hospitality venues.
Bench Seating
Custom laminated foam cushions designed to provide lasting comfort, support and durability for commercial and residential bench seating.
Mattress Toppers
Layered foam mattress toppers engineered to combine pressure relief, comfort and support for a more restful night's sleep.
Laminated Cushions
Custom laminated foam cushions combining soft comfort layers with supportive base foams for enhanced seating comfort and durability.
Frequently Asked Questions
Custom Foam & Lamination Information
Open each section below to learn more about laminated foam, custom cutting, foam grades and our Foam Studio.
Laminated foam is created by bonding two or more foam grades or thicknesses together to form one finished piece. This allows the construction to be tailored for comfort, support, durability or cost.
Foam lamination allows softer and firmer foam grades to be combined in one cushion. This can improve comfort and support while using premium foam only where it is needed most.
Yes. Different foam grades can be bonded together to achieve specific comfort levels, support characteristics or technical requirements depending on the application.
Choose your shape, then enter all measurements in the Size step, including the total foam thickness. Match the lettered arrows to the measurement boxes and choose centimetres, millimetres or inches. In Foam, select your main grade and optional top or bottom layers. All layers share the total thickness you have chosen; you can adjust their individual thicknesses in Size.
Add stockinette or Dacron / polyester wrap in Finish. Available designs can be priced and added to your basket; other shapes or sizes can be sent to our team for a quote, with an optional drawing attachment.
No. Alongside standard rectangular foam, we manufacture shaped cushions, CNC-cut components, packaging inserts and bespoke fabricated foam parts for a wide range of applications.
Yes. Our team can recommend suitable foam grades or laminated constructions based on the intended application, required comfort, support, durability and available budget.