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How to Upholster a Chair Using PU Foam Sheets

How to upholster chair with polyurethane foam sheets

What is Polyurethane Foam?

Polyurethane foam (PU Foam) first came into existence in 1937 when Dr. Otto Bayer (head of research at IG Farben), discovered the polyaddition for the synthesis of polyurethanes out of polyisocyanate and polyol. Woah! That’s more polys than a truck full of parrots…

Is the science of PU foam making absolutely zero sense to you right now? That’s completely understandable. All you really need to know about polyurethane foam sheets (or PU foam sheets for short) is that they’re great!

Do you have a favourite chair that’s seen better days? Planning on granting said chair some much needed TLC, but don’t know where to begin? Read on to discover how PU foam sheets can help change it into a superior version of its former self.

Chair Upholstery – Where to Begin

First things first, you’re going to need PU foam sheets! GB Foam proudly offers an extensive selection of PU foam sheets suitable for upholstery. To discover what’s right for you, we highly recommend checking out our Upholstery Foam Sheets page.

Once you’ve picked the perfect foam, you’ll need a couple more bits. Firstly, we really recommend getting a seam ripper. They’re extremely cheap, easy to obtain and will make the job much easier on your hands.

You’re also going to need some new fabric (most chairs require approximately 4.5 meters). Sure the old stuff looks ok, but it could be so much better. Remember to pick a fabric that not only looks good but is also hard wearing.

Other items will include a staple gun, scissors, and straight pins.

Upholstering Your Chair with PU Foam Sheets

Ready? Got everything you need? Then let’s begin.

Start off by taking your seam ripper. Can you guess what’s coming? That’s right, locate your cushions seams and use this tool to rip the threads. Once completed, remove the old fabric.

Once removed, locate your PU foam sheets. Assuming that they’re readily cut to size, place the sheets over the chairs existing foam. This will help provide superior comfort, a uniformed finish, and additional protection.

When adding your fabric of choice, a pro tip is to not entirely staple one side before the opposing side. Instead, make sure the fabric is taut, place a staple in one area and then repeat on the opposite side. This will help to create a neater finish, whilst helping to avoid potential accidents.

Here’s the tricky part, corners! Naturally, you’ll want a clean finish for all areas of your chair – Take your scissors and cut a vertical notch in the fabric corners. Neatly fold over the hanging edge at the bottom and tuck it around the chair leg; staple it to place. Next, fold the second edge and staple it over the other piece. Cut a small slit in the bottom of the fabric and use a straight edge to push the excess fabric to the roof of the chair. Repeat as necessary.

For the back of your chair, ensure the fabric you use is lined up appropriately; you don’t want mismatching patterns. Use straight pins to secure the fabric along the back edge of the chair. Once neat and secure, you’re finished! Well done.

A New Comfy Chair Thanks to PU Foam!

You’ve tackled the hard part, now it’s time to enjoy the fruits of your labour. That once dingy and uncomfortable chair now looks fantastic and thanks to the PU foam, feels even better!

Now you know what to do, why not try another chair? Perhaps one that provides more of a challenge?

Many people make successful side businesses from upholstering old furniture, perhaps you could as well? Whatever you decide to do, GB Foam has all the PU foam you’ll need to make your project a reality.

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