Welcome to Foam Factory

Supplies Needed to Complete this Task
You will need the following: Pen, Paper, Foam cut to size, fiberfill, tape measure, straight edge, stapler and scissors.

Calculating size for Fiberfill
Using the measurements you have from the foam cut to size, calculate the amount of fiberfill needed to cover your cushion. You can do this by using the following formulas. After you have figured the size of fiberfill needed, record the size with your pen & paper

Cutting the Fiberfill Needed for your Foam
With the measurements recorded for the size fiberfill needed, measure and cut the fiberfill as shown in picture 1-1 (see below). If you are not good at cutting straight lines, you can use a long straight edge as a guide to cut along. After you have completely cut the fiberfill to size, fold the fiberfill over so that the cushion is evenly centered inside the fiberfill wrap. There should be equal overhangs on both sides and the back of the foam. See picture 1-2 and 1-3. MAKE SURE that the smooth, unstapled fiberfill side going to be on the front of your cushion.

Stapling the back of the Cushion Take your stapler and continue by stapling the back of your cushion. The finished step should look similar to picture 2-4. The process itself is similar to wrapping a present, but instead of using tape to hold the wrap, you are using staples. Experience has shown that the best way to hold the cushion in place while stapling is to wedge the cushion in-between your thighs and the edge of the table. The front edge of the cushion should be facing down and the back edge should be facing up. The cushion's back edge should be about even to your stomach so that it is within easy reach of your hands as shown in the pictures below. OK, now that the cushion is in place start by pulling slightly up and folding the upper fiberfill lip down toward you. See picture 2-1. Then pull lower fiberfill lip slightly up and down away from you. See picture 2-2. Then staple both the upper and lower lip together. See picture 2-3. Continue this process until there is a staple about every 2 to 3 inches along the back of the cushion. However, as in picture 2-4 both the left and right edge of the back of the cushion are unstapled. Leave about 2" off the edge of the *foam* unstapled for both the left and right sides.

Stapling the sides of the Cushion - Part 1
Wedge the cushion between your thighs and the table. Face the left side down and the right side of the cushion up. Notice how we are working near the back of the cushion and not the front. There are different steps for the side front of the cushion. Start by folding the upper lip down as shown in picture 3-1 and be sure to stretch a bit as you make each fold. Then collapse the upper lip down as shown in picture 3-2. Repeat the same steps for the lower lip till your cushion looks like picture 3-4. Then put two or three staples in the edge to hold the folds in place. Repeat this process by rotating the left side up and the right side down. The finished result should look like picture 3-5.

Stapling the sides of the Cushion - Part 2
Wedge the cushion between your thighs and the table. Face the left side down and the right side of the cushion up. Notice how we are working near the front of the cushion and not the back. Start by folding the center down (picture 4-1) remember to stretch a bit as you fold, then the upper lip down (picture 4-2) and finally the lower lip down (picture 4-3). Put two or three staples in the fiberfill to hold the folds in place. Repeat this process to the left side by rotating the left side up and the right side down.

Stapling the sides of the Cushion - Part 3
Wedge the cushion between your thighs and the table. Face the left side down and the right side of the cushion up. Staple the center of both the left and right sides of the cushion, similar to how you stapled the back of the cushion, putting a staple about every 2 to 3 inches apart. Repeat this process for the left side by rotating the left side up and the right side down. The finished product should look similar to the picture at the left.

(Optional) Smooth the Sides
With medium to heavy weight fabrics, this step in not required. However, for lighter fabrics this step may be necessary. Using your scissors, trim the excess fiberfill sticking out of the cushion. Be careful not to cut too much fiberfill out. Also, be careful not to cut the staple, and do not to cut the staple out of position.