GB Foam ISO9001 GB Foam Celebrating 40 Years in Business

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Need Help? Call: 01494 44 11 77

Foam Cut To Size with next day delivery

Order Replacement Foam in 5 Easy Steps

With over 25 standard foam cut to size shapes to choose from and a full custom bespoke service, GB Foam Direct offers a full solution for your foam replacement needs. With only 5 easy steps our website is super simple to use. Jump straight to Step 1 below or see our full guide.

Super Fast Foam Delivery

Super Fast Delivery

All orders placed before 11:00am will be despatched for next working day delivery

5 Year Foam Guarantee

5 Year Guarantee

Our products come with a 5 year guarantee against faults in manufacture.

Flame Retardant Foam

Flame Retardant

Our entire range exceeds UK safety and flammability standards.

Buy Foam Cut To Size - STEP 1 - Choose Your Shape

Select Foam Shape

1. Select Foam Shape Below

Choose from our wide selection of foam shapes below. If you require assistance please use our online chat. Our foam specialist team are on hand to help you every step of the way through our simple 5 step cut to size foam wizard.

A Few of Our Clients

We’ve worked with many influential companies over the years, all of whom have sought expert knowledge and high-quality products at affordable prices. We’re proud to say that these clients all found and received what they needed working with us. Take a look for yourself and see the brands that have benefited from our expertise.

GB Foam Direct – The UK’s Foam Cut To Size Specialists

We specialise in foam cut to size and shape. Whether you are looking for replacement cushions for your boat or caravan or something more specialist we can help.

For over 40 years we have been supplying traders and various retail outlets with our quality, fire retardant foam. In recent years, other companies in the UK have emerged supplying inferior cheap foam to the public. We pride ourselves on having the best materials in the UK. To put an end to inferior products we are cutting out the middle man to bring quality foam cut to size, at the same great price, delivered directly to your door.

Please use our handy Online Foam Cut to Size Calculator for a simple fast quote. If you can’t find what you are looking for or you need some help, our specialists are on hand to help you make the perfect choice for your project. Give us a call today on 01494 441177 or use our live chat.

ORDER FOAM CUT TO SIZE – With 5 Easy Steps

Select Foam Shape

1. Select Foam Shape

Choose from our 20 default foam shapes or choose a custom shape for bespoke designs.

Measure Foam Cushions

2. Measure & Enter Size

Carefully measure your current cushions and enter the size in mm, cm or inches.

Select Foam Type

3. Select Foam Type

We stock ten different grades; from soft budget to luxury memory foam cut to size.

Foam Additions

4. Choose Additions

For sofa cushions we recommend adding dacron & stockinette to make it easier to slide into the original cover and add loft.

Place Your Foam Order

5. Place Your Foam Cut To Size Order – For Next Day Delivery!

All orders placed before 11:00am will be despatched for next working day delivery as standard.

GB Foam Direct Factory - Foam Cut To Size

How Is It Made – The GB Foam Direct Philosophy

As the UK’s largest foam suppliers, our factory is equipped with the latest CNC cutting technology and throughout the years we have employed the most talented freehand cutters in the industry. Many members of the team have worked for the company for several decades and their attention to detail and quality control is something that only comes with years of knowledge and experience.

We have many customers who started with us in 1976 and are still working with us today, which we like to think reflects on our vision to be the most dynamic seat foam converter in our industry. For us, no job is too big or too small. We offer the same level of service and delivery whether you are a retail customer ordering one piece of foam cut to size from home, or a large manufacturer ordering daily.

Foam Cut To Size FAQs – Frequently Asked Questions

Need help? We never want any of our customers to be in the dark when ordering from us. Whether it’s a question about a certain product that we offer or something to do with delivery, we’re always glad to help. If you’d like to speak to somebody directly regarding our services, you can always contact us. We’re open from Monday – Thursday 9:30 AM until 4 PM and from 9:30 AM until 3:00 PM on a Friday. During this time, we can take your calls and answer any questions you may have regarding our services. You can also email us via, use our live chat feature or fill out the form on our contact page. Whichever you prefer.

Alternatively, below you will find a list of frequently asked questions regarding our services. Why not check here first, to see if we’ve already answered your question?

How Long Will It Take For My Order To Arrive?

Orders placed between Monday – Thursday before 11:00 AM are generally dispatched for delivery on the next working day. This may, however, vary, depending on which zone of the United Kingdom you are located in. For further information regarding our shipping zones and to find out which zone you fall under, visit our delivery page.

Can I Order From You If I Don’t Live in the UK?

You can. We’ve served many happy customers over the years who were located overseas. All we ask is that you contact us prior to delivery in order to confirm shipping details.

I’m Ordering On Behalf of a Business, Can I Receive A Discount?

We’ve supplied quality products to many businesses throughout the years. If you’re looking to regularly order in multiple quantities for your business, contact us to discuss our trade contracts. This is the best way to receive what you need for your business at the very best price.

Can I Collect My Order Directly From You?

If you require your order on the very same day, we do allow our customers to collect directly from our factory. This is dependent on whether or not the materials for your order are in stock at the point of sale. To be safe, we advise that you contact us prior to collecting in order to ensure that your order will be ready.

I Need Something Unique Made, Can You Help?

We certainly can. Our factory contains some of the most advanced cutting machinery around. We’re able to create everything from simple designs to ones that are much more intrinsic. To discuss our design and development services in greater detail, be sure to contact us directly.

Who Do Your Services Cater For?

The short answer is anybody that needs them. In greater detail though. Some people come to us to replace their old sofa cushions, whilst upholsterers visit our website to buy their much-needed materials. In fact, we’re proud to cater to more than twenty different market sectors including aerospace, hotels and hospitality, the medical and healthcare industry, office seating, contract seating and much, much more!

Do You Offer a Guarantee with Your Products?

Yes, we do! In fact, we offer a 5-year guarantee against manufacturer faults across our range of products. In the unlikely event that we’ve made an oversight concerning your order, which causes a fault, we’ll replace it free of charge providing a claim is made within the 5-year window.

Are Your Products Fire Retardant?

Yes! Safety is one of our most highly valued priorities. This is precisely why we ensure that our products not only meet but exceed UK fire safety regulations. When you purchase from us, you can be assured that your product is safe and suitable for use.

What Payment Options Do You Accept?

We accept all major credit cards and debit cards. Or, if you prefer, you can also pay with PayPal on our website. If you have any issues with payment online, we’re also able to take orders over the phone. Simply contact us on 01494 441177.

Can We Find You on Social Media?

We’d love for you to follow us on Social Media! We have a range of social media accounts across various platforms including Facebook, Twitter, Instagram, Google+, Pinterest and more! Stay up to date on all of the latest news and look out for our monthly mattress giveaway competition.

Are My Details Safe With You?

Our website uses a Comodo SSL Encryption in order to protect your personal details. If you look at our website URL, you will notice that at the beginning it reads https:// as opposed to http://. The “S” stands for “secure”. When you view a page on our website, it becomes encrypted whilst traveling between servers. This makes it impossible for your personal details to be intercepted by identity thieves.

What is the Difference Between HTTP AND HTTPS?

All communications sent over regular HTTP connections are written in ‘plain text’. This means that they can be read by any hacker that may manage to break into the connection between your browser and the website. An HTTPS connection, on the other hand, encrypts all communication between your browser and the website, meaning that it cannot be read by anybody but the person placing the order. When making purchases online, it is always advisable to look out for the padlock icon and HTTPS. This is the best way to ensure that your personal details remain safe and out of the hands of fraudsters.

Can I Just Replace My Sofa Seat Cushions?

Of course, due to the nature of our services, you can replace any part of your sofa cushions that you desire. You can do the same for your sofa back cushions as well if you wish. With this said, however, we do recommend replacing all of your sofa cushions in order to maximize comfort and maintain consistency. Whatever you need cut to size for your sofa, we’re happy to oblige.

Are You a Multi-Purpose Supplier?

Yes! Our services are utilised by a multitude of different people all from different backgrounds and professions. We supply our materials to a wide range of market sectors all around the world. We’re always looking to expand upon our services also if you’ve got a particular idea in mind and can’t find any mention of it on our website, feel free to contact us and we’ll see what we can do for you.

Do You Offer Trade Discount?

We do. If you intend to regularly purchase from us and want to make great savings, call or email our sales team today to discuss opening a trade account. This is the best way to purchase materials for your business and maximise your profit potential.

What is Your Quality Policy?

We are ISO 9001 approved and create all of our products in adherence to this standard. We aim to provide quality products at reasonable rates and through a reliable service to all of our customers. Your satisfaction is our main priority.

Do You Have A Blog?

We do indeed! If you’re looking for inspiration, news on the industry or just some light reading material head on over to our blog today. Perhaps it’ll help spur your next big idea!

Are Your Products Made in the UK?

Yes! Everything we sell is made in England within our factory in High Wycombe. We employ some of the most talented people in the industry to make the products you buy. Your orders are always in capable hands when you purchase from us.

Do You Recycle?

Yes! In fact, 98% of the scrap materials that we use are recycled and repurposed. That doesn’t mean to say that what you purchase from us is second-hand, all of our products are 100% new and unused. We just recycle the scrap offcuts.

I Can’t Find What I’m Looking For on Your Website, Can You Help?

Of course! We want all of our customers to be 100% satisfied when shopping with us. If you can’t find exactly what it is that you’re looking for contact us and we’ll do our best to point you in the right direction.

How Many Different Foam Cut to Size Shapes Do You Offer?

Technically we offer an almost infinite number of shapes, via our custom shape option. However, to make things easier for you, we’ve also created a number of different frequently used shape templates. These include templates for sofa cushions, dining seats, bar stools, bay window seats, boat mattresses, caravan cushions and much more. Not including our custom template option, there are a total of 24 different shapes to choose from.

Do You Sell Mattresses?

We do! In fact, we’ve been specialising in the design and production of mattresses for many years. We’ve supplied to the likes of Dreams and even once owned our own mattress store way back when. Nowadays we mostly sell our mattresses online and predominantly through our brand Lion Mattresses. If you’re looking for the best mattresses at the very best price, then you’ve come to the right place. We also sell a variety of pillows, mattress toppers and bed guards.

What is Stockinette?

Stockinette is a special material that we are able to apply over the top of sofa cushions in order to make them much easier to insert into their casing. This is an extra feature we offer available at an additional charge. You will be asked whether or not you would like to add stockinette to your order when placing your order. For easy application, we definitely recommend stockinette.

What is Dacron?

Dacron and stockinette go hand in hand which is why we offer them both together. Stockinette makes it easier to put cushion foam cut to size into cases. Dacron helps to give your cushions even more loft, a fuller fit for your cushions and further enhances comfort.

I’m Looking to Make My Own Bean Bag.

We crumb our offcuts so that they can be used for a variety of purposes. One popular use for crumb filling is within homemade bean bags. This provides an alternate filling that’s not only more practical, but also more comfortable. Whether you’re making a beanbag from scratch, or filling an old cover, our crumb filling is ideal. Unsure how much crumb filling you’ll need for your bean bag? As a rule of thumb, 1kg of crumb filling is enough to fill one cubic foot within your bean bag. This will however differ slightly depending on your firmness preferences. If you want your beanbag to be firmer, we’d suggest you order a little more. You can also use our handy beanbag filling calculator to work out the volume of your beanbag. Simply measure it and input the details for an instant quote.

Industries We Supply To

We supply materials to many unique and varying industry sectors. When customers need to source the right materials for the job, we’re always happy to help. Whether it be products for the Film and TV industry or the Automotive and Industrial, we’ll find a solution. In the past, we’ve supplied materials for applications in:

Acoustic and Soundproofing – Customers turn to us when they need to acoustically treat a recording studio, home cinema, rehearsal rooms and more. We supply both commercially and residentially.

Aerospace – We develop materials suitable for both aviation and space flight to provide, safe, practical and comfortable journeys.

Auditoriums and Theatres – Whether it’s new seating or acoustic treatment you need, we can help.

Automotive and Industrial – We create custom cut trays for the automotive industry for use in production lines, seat padding and more.

Bar Seating and Bench Seating – New builds or refurbishments. We offer superior seating comfort.

Beddings and Soft Furnishings – We’ve supplied large quantities of soft furnishing and beddings for many businesses, including the NHS and private healthcare organisations.

Boating and Marine – Fixing up your boat? We’re able to offer superior marine materials which are suitable for use on the water.

Case Inserts – We use advanced cutting machinery to create bespoke case inserts which help protect your items of value.

Display Presentation Boxes – Give items a premium appeal with custom cut inserts for display & presentation boxes.

General Upholstery – Whether you’re a professional upholsterer or a hobbyist, we have a range of upholstery supplies to suit your needs.

Gym Pits – We professionally cut cubes and logs to be used in Gym Pits worldwide. If you’re looking to create a Gym Pit or need to refresh your old one, we’ll be happy to help.

Hotels and Hospitality – Many customers from the hotel and hospitality industry turn to us to provide quality products for their business.

Industrial Packaging – When journeys get bumpy in transit, our materials help to keep them safe.

Interior Design – Need something extra special? We have the machinery at hand to create almost anything you can imagine.

Medical and Healthcare – We develop products to provide rest and relaxation for those with medical requirements. Our products help to provide rest and relaxation for those in need.

Military (MOD) – We can supply lightweight, military grade products which are tested and certified to (MOD) specifications.

Museum Exhibitions and Galleries – We create custom housing for the most precious items and works of art which help to keep them safe.

Office and Contract Seating – From small to large buildings. Our office and contract seating materials help to provide comfort throughout the working day.

Retail Packaging – Our materials can also be used to house products in retail packaging. The results and both practical and stylish.

Sports and Leisure Facilities – From crash mats to gym pits, our products help to keep people safe during the most intensive of activities.

Staging and Company Exhibits – If you’ve got a particular vision in mind for an exhibition, we can provide products to make it a reality.

Technical – We create specialised products through advanced fabrication techniques. If you can’t find what you need, we’ll work to develop a solution.

Trampoline Parks – We supply gym pit materials for trampoline parks worldwide. Our technically advanced techniques mean that we can develop a unique, effective and visually appealing product for your trampoline park.

TV, Film, and Theatre – Many companies turn to us to provide bespoke materials for TV, Film and Theatre. From upholstery sheets to unique custom-designed props.

Foam Cut to Size Reviews

  • 5 out of 5

    Mark Peterson

    Recently purchased some replacement cushions for my sofa after the old ones began to sag. The delivery was really quick and the cushions fit like a dream. Would highly recommend your services. Thanks

  • 5 out of 5

    Justin Walmsley

    Found this website on Instagram and decided to see if I could get a new mattress made for my campervan. The staff went above and beyond to help me out. I couldn’t be happier with the service I received.

  • 5 out of 5

    Frank Hewitt

    Thanks for all your help. Ordered your high density foam cut to size, received next day and no qualms at all. Will return in the future.

  • 5 out of 5

    Melanie Knight

    So glad I found this website! We recently bought a sofa and the cushions were just terrible. I really thought I was going to be stuck with it until a friend referred me here. Now my sofa feels great. Thank you!

  • 5 out of 5

    Coleen Haywood

    Really great website and easy to use compared to other places I’ve visited. I called to confirm a couple of details and Lauren was very helpful so an extra big thanks to her.

  • 5 out of 5

    Nick Hubbard

    Recently ordered some foam cut to size for a brand new set of cushions on my boat. They were made to my exact specifications and feel fantastic. Arrived fast as well.

  • 5 out of 5

    Keith Harrell

    Bought some foam cut to size to upgrade our caravan seats since the old ones had seen better days. The new ones made a bigger difference than I expected and are really comfy. The measurements were dead on and like promised they arrived the very next day. Great service.

  • 5 out of 5

    Terry Hodges

    Excellent through and through, can’t recommend you more highly. Next time I need foam cut to size I will be back again.

  • 5 out of 5

    Cheryl Bishop

    A friend of mine recently bought some foam cut to size from here for a new window seat. It looked great and thought I’d have a shot at doing it myself. Really pleased with the service I received. Haven’t gotten around to finishing the job yet but everything service wise was excellent.

  • 5 out of 5

    Grant Yates

    After sitting on my new cushions I’ll never use fibre ones again. The difference is night and day compared to the old ones that used to be in my sofa.

  • 5 out of 5

    Daniel Burnham

    Perfect. Couldn’t have expected any more from these guys, they went above and beyond.

  • 5 out of 5

    Claudia Garner

    Needed some foam cut to size for a full sofa suite after realising how uncomfortable the original cushions were. These have made a huge difference! Arrived on time, easy to fit and very comfortable. Highly recommended!!

  • 5 out of 5

    Martine Smith

    I’ve been ordering from here for a while now. I really like how user friendly the website is and my orders have always arrived on time and as expected. Thanks.

  • 5 out of 5

    Elliot Howland

    Thank you for all of your help with my recent order. Jane on the phone was very kind and helpful. My order arrived today and I am very pleased with it.

  • 5 out of 5

    Helena Joiner

    Easy to use website, fast delivery and fantastic high density foam!

  • 5 out of 5

    Cathryn Woodcock

    Great service. Ordered Wednesday morning arrived the morning after.

  • 5 out of 5

    Claire Thompson

    Your website is fantastic. I followed your how to measure cushions guide and my sofa cushions arrived super quick.

  • 5 out of 5

    Sarah Joynes

    I never needed foam cut to size before until our puppy Angus destroyed the sofa. The old cushion is being turned into a dog bed and we are now sitting on the ones you sent us. Great service and a lifesaver; so happy we didn’t have to buy a brand new sofa.

  • 5 out of 5

    Richard Newman

    100% my new upholstery product supplier. Price was superb compared to my old supplier and my order arrived really fast. Will be back to buy again soon.

  • 5 out of 5

    Andy Gardener

    First-rate service, fast delivery and great quality. 5 stars!

  • 5 out of 5

    Debra Young

    My sofa is like new again. We can’t thank you enough. Will definitely recommend you to family and friends.

  • 5 out of 5

    Angela Simmons

    Wow just wow. What a difference it made! I was getting tired of plumping up the feather cushions on our corner sofa. Chose your foam cut to size service and I am over the moon with the results.

  • 5 out of 5

    Peter Clark

    Upgraded our caravan cushions. We took the high density foam to an upholsterer to get them covered. The caravan has been upgraded overnight just by switching the old ones out.

  • 5 out of 5

    Jim Hobson

    Used your foam cut to size service for my garden furniture in summer. There was a leak in our shed and the old cushions had gone mouldy. They are more comfortable than the old ones and we even updated the covers to match our new fire pit.

  • 5 out of 5

    Jane Mitchell

    Created some window seating using your custom shape tool. Made the covers myself with material from the market. Husband is well impressed.

  • 5 out of 5

    Amy Ward

    Already recommended your cushion filling to our friends. They actually bought some of your beanbag fillings and they love it too.

  • 5 out of 5

    Deborah Hill

    I used to get my foam cut to size locally until I realised it could be done online. It’s actually worked out cheaper this way and it’s so much easier.

  • 5 out of 5

    George Cartwright

    Great to see furniture coming back from High Wycombe. I lived there during the golden age of British manufacturing of furniture. We upgraded our old Parker Knoll chair using your website. It looks as good as it did 20 years ago. Thanks again to Jane for her help on the phone.

  • 5 out of 5

    Irene Watson

    Big thanks for taking my order over the phone. I struggle with the internet but thanks to your customer support they talked me through each step of the way.

  • 5 out of 5

    Karen Barnes

    The package just arrived in. The kids are happy playing in the box it arrived in whilst I get comfortable on my upgraded couch. Can’t thank you enough.

  • 5 out of 5

    Charlie Turner

    You guys are awesome! My wife is that impressed with the upgraded sofa she finally agreed with me that we didn’t need a new one afterall.

  • 5 out of 5

    Mary-Anne Campbell

    Well made, good quality product cut exactly to size. Very pleased with purchase, thank you.

  • 5 out of 5

    Michele Holland

    A revelation! Easy to order, quick delivery and made the job so simple! Will definitely order from them again.

  • 5 out of 5

    Vicky Potts

    Thanks, this has replaced a 30 year old bed/ sofa in our campervan. I’m really looking forward to a more comfortable sleep next time we use the van.

  • 5 out of 5

    Colin Townsend

    We ordered on the Thursday, and they arrived on the Monday, and they are perfect. Our settees, which were second hand when we had them a few years ago, have been rejuvenated, and look and feel superb, better than when we first had them. Superb quality, superb service. Thank you.

  • 5 out of 5

    Janine Ellis

    This is the second time we have purchased from this company. Highly recommend. Great value, fast, fuss-free delivery. Great company. Thank you.

  • 5 out of 5

    Charlotte Burbridge

    Have just bought two replacement cushions for our old family sofa which we have had for decades! Such a great quality sofa that can’t be replaced, but the cushions were sagging. They are now revived and back to their original firmness! Excellent! Will be doing the rest of the cushions for the sofa soon.

  • 5 out of 5

    Anne Gavin

    Was a problem with how I had given my measurements online. A lovely lady (can’t remember her name) rang me straight away to double check with me and clarified what they were. So grateful as I wouldn’t of got the right cushion. Great quality and value for money. Can highly recommend this company. Thank you once again.

  • 5 out of 5

    Sophia Seroff

    Super quick and great quality. The made to measure cushion came within days and was perfectly cut to size and true to description. Very happy and would use again!

  • 5 out of 5

    Nicola Edwards

    Great quality, feels like a new sofa. Really happy with our new sofa cushions, it has given us a new sofa, we wanted a bit more wear out of the sofa with having a toddler and baby on the way, without the expense of having to buy a whole new sofa.

  • 5 out of 5

    Joanne Edwards

    Low cost revitalised armchair – brill service. Chose to order from this company as my parents had a great experience ordering by phone last year and they recommend you. Easy online ordering and measuring advice with very good value for money too. I was able to measure and order with confidence and the cushion was a superb fit. Fully recommend.

  • 5 out of 5

    Heidi Phillips

    I was unsure which was the best firmness level I needed. A quick call and I was greeted with a very helpful assistant who talked me through the options. Very good value and even better delivery.

  • 5 out of 5

    Magda Olivier

    Great service, excellent quality. Very easy to order, delivered on the exact requested time. The product is well-packaged and of an extremely good quality, cut to perfection.

  • 5 out of 5

    Debbie Pitt

    With the measurements graphics, it was so easy to see what you are getting the right shape when you put in the size. The service was brilliant and the cushions came in days. I wanted them for old chairs with sagging seats and now I don’t have to get them re-upholstered and hopefully they should last another 20 years!

  • 5 out of 5

    Judy Patterson

    The website was quick and easy and I received everything next day. Can’t fault anything at all. Will definitely recommend you.

GB Foam Celebrating 40 Years in Business
40 Years In Business

GB Foam have been offering foam cut to size from our factory since 1976.

Foam Made In The UK
Hand Made In The UK

We employ the most talented freehand foam cutters in the industry.

GB Foam ISO9001
ISO 9001 Quality

Our team work to the ISO 9001 quality standards to guarantee only the best.

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