Foam Sheets for Upholstery, Packaging and Acoustic Use

Choosing an upholstery foam sheet

Upholstery foam sheets are used to replace or create seat cushions, back cushions, chair pads, window seats, headboards, mattress components and general furniture padding. The right foam depends on the job it needs to do. Softer grades are better suited to light padding and headboards, while medium, firm and Reflex grades provide the support and recovery normally required for seating.

Foam firmness, density and intended use

Firmness describes how soft or firm the foam feels under load, while density relates more closely to the amount of material within the foam and its expected durability. These properties should be considered together. Average-soft foam is intended for light padding rather than seating, medium and high-firm grades suit a wide range of furniture projects, and Reflex foam provides responsive recovery for premium seating and mattress applications.

Severe very firm foam is useful where strong support is required in a relatively thin cushion. Reconstituted foam is a dense, robust option for contract seating, gym mats and other demanding applications. Cot-safe foam is a specialist nursery grade and should only be used for the applications described on its product card.

Sheet size, thickness and fire performance

Choose a sheet size that covers the required finished dimensions with allowance for trimming where necessary. Thickness has a major effect on comfort and support, so a seating cushion should be specified differently from a headboard or light padding project. Fire performance also varies by grade and intended use. Check the product information and the relevant foam technical data sheet before ordering for furniture, commercial or regulated applications.

For a complete sleeping surface, compare our foam mattresses. To add a separate comfort layer to an existing mattress, view our memory foam and egg-crate mattress toppers.

Specialist foam for packaging, protection and industrial use

Special-use foam sheets are selected for their protective, water-resistant, anti-static, sealing or load-bearing properties rather than seating comfort. The range includes lightweight packaging foam, AS22 pink anti-static foam, closed-cell polyethylene, Plastazote® LD33, Ethafoam STPE200 and EPDM closed-cell rubber.

Packaging and anti-static foam

Flat and convoluted packaging foam can line flight cases, briefcases, boxes and transit containers. The flat grade creates a consistent protective layer, while the convoluted egg-crate profile is useful for case lids and for holding irregular items more gently. AS22 anti-static foam is designed for packaging electronic components and other items that need protection from electrostatic charge during handling, storage or transport.

Closed-cell polyethylene, Plastazote and Ethafoam

Closed-cell foam does not absorb water in the same way as open-cell polyurethane foam. EFP30 is a versatile rigid polyethylene grade, while EFP45 is denser and more rigid. Plastazote® LD33 is a nitrogen-expanded cross-linked foam available in several colours for presentation, packaging and specialist fabrication. Ethafoam STPE200 is a semi-rigid non-cross-linked polyethylene foam used for cushioning, separation and transit protection.

EPDM rubber and self-adhesive backing

EPDM closed-cell rubber is flexible and suitable for sealing, gasketing, anti-vibration and insulation applications. Several specialist sheets are available with optional self-adhesive backing to simplify installation. The adhesive option should be chosen according to the surface, environment and intended use. Fire performance differs between products, so always check the individual product card and technical data sheet.

For an unusual application or help choosing between similar grades, contact the All Foam team before ordering.

Acoustic treatment for reducing echo and reverberation

Acoustic foam sheets absorb reflected sound energy within a room or enclosure. They are commonly used to reduce reverberation, flutter echoes and harsh reflections in recording spaces, rehearsal rooms, media rooms, machinery enclosures and other areas where clearer sound is required.

Flat and convoluted acoustic foam

Flat acoustic foam provides a consistent thickness across the sheet and is straightforward to position on walls, ceilings and inside enclosures. Convoluted acoustic foam has an egg-crate profile that increases the exposed surface area and can be useful where a profiled finish or additional airflow is preferred. Both types are available in standard charcoal acoustic foam, while Class 0 products provide a higher specified level of fire performance for suitable applications.

Acoustic treatment is not structural soundproofing

Acoustic foam is intended mainly to control sound reflections within a space. It does not, by itself, create a complete barrier against sound passing through walls, floors or ceilings. Effective sound isolation usually requires a combined construction using mass, isolation, sealing and absorption materials.

Optional self-adhesive backing can make installation easier on clean, suitable surfaces. Always confirm the product's fire classification, thickness and installation requirements in the relevant acoustic foam data sheet before use.