A Beginner’s Guide to Foam Grades and Their Uses

With the wide range of foam products and suppliers out there, it might be tricky to choose the right foam type for your upholstery project, especially if you are not familiar with terms like foam grades and density.

To make it all easier, we’ve put together a brief guide to foam grades and their intended uses to help you pick the right foam for the job.

Premium Soft Grade 30 Foam

The Grade 30 is a high-quality and very soft foam. Due to its softness, it’s not recommended for seating purposes. However, the Grade 30 is ideal to use for: 

  • back cushions  
  • soft mattress toppers 

 Medium Density Packaging Foam

The Packaging Foam Sheet is a medium density dark grey foam. The Packaging Foam can be used for: 

  • packaging and protecting fragile items during transit 
  • crafting projects  
  • upholstery repairs  

Budget Grade 33 Foam

The Budget Blue Grade 33 is a popular high-density versatile foam, regularly purchased by our clients. With its durability, the Grade 33 Foam is a popular choice for: 

  • caravan seating
  • dining pads
  • various craft projects. 

 Premium Blue Grade 39

The Premium Blue Grade 39 is a high-density foam, perfectly suited for high-use items. Upholsters pick the Grade 39 is suitable for: 

  • sofa cushions 
  • boat seating 
  • caravans
  • campervan seating 
  • upholstery repairs  
  • craft projects. 

Premium Grey Grade 40

The Premium Grey Grade 40 is a very luxurious high-density foam with a high resistance and a bounce-back touch. 
The Grade 40 is perfect for use in sofa seat replacements providing comfort and resistance. 

6lb Chip Grade Foam

The 6lb Reconstituted Chip Foam is a very firm grade, that offers enhanced durability. It’s a cost-effective and environmentally friendly foam solution. made of recycled foam chips. The 6lb Chip Grade is ideal for: 

  • hard-wearing commercial environments 
  • gym mats and church kneelers 
  • padding restaurant, bar and bus seating

 If you are looking to give your old sofa or furniture cushions a second life, look no further! At Foam Superstore, we offer quality foam cut to size and custom shape, according to the exact specifications you provide us with.

Foam Grades Explained

Foam grades are a critical aspect of understanding and choosing the right foam material for various applications. These grades are used to classify foam based on its density, firmness, and overall quality. Foam density is measured in pounds per cubic foot (lb/ft³) or kilograms per cubic meter (kg/m³). The higher the density, the more durable and supportive the foam is likely to be.

  • Low-Density Foam: Foam with a low density is typically softer and less supportive. It is often used for applications where comfort is a primary concern, such as mattress toppers or decorative cushions.
  • Medium-Density Foam: This foam grade strikes a balance between comfort and support. It is commonly used for sofa cushions, dining chair pads, and some mattress layers.
  • High-Density Foam: High-density foam is known for its durability and firmness. It is ideal for applications where extended use and support are essential, such as mattress cores, seat cushions, and automotive seating.

High-Density Foam

High-density foam is a popular choice for various applications due to its outstanding durability and support. Here’s a more in-depth look at high-density foam:

High-density foam typically has a density of 2.5 lb/ft³ (40 kg/m³) or higher. This density level allows it to withstand regular use without losing its shape or becoming excessively compressed.

Key Characteristics of High-Density Foam:

  • Longevity: High-density foam is designed to last, making it suitable for applications where durability is crucial.
  • Firmness: It offers excellent support and maintains its firmness over time, making it ideal for seating and mattress cores.
  • Comfort: While high-density foam is firm, it still provides a level of comfort, ensuring that users do not feel like they are sitting or sleeping on a hard surface.

Common Uses for High-Density Foam:

  • Mattress Cores: High-density foam is often used as the core material in mattresses, providing the necessary support for a restful night’s sleep.
  • Seat Cushions: It is a popular choice for seat cushions in furniture and automotive seats, ensuring comfortable and supportive seating.
  • Exercise Equipment Padding: High-density foam is used in gym equipment and yoga mats to provide cushioning during workouts.
  • Industrial Applications: In industrial settings, high-density foam can be used for packaging, insulation, and vibration dampening.

Foam Grade Chart

A foam grade chart is a valuable resource when selecting the right foam for your needs. This chart categorizes foam grades based on various factors, allowing you to make an informed choice.

Sample Foam Grade Chart:

Foam Grade Density (lb/ft³) Firmness Common Applications
Low 1.5 – 2.5 Soft Mattress toppers, cushions, pillows
Medium 2.5 – 3.5 Medium Sofa cushions, dining chair pads, some mattresses
High 3.5+ Firm Mattress cores, seat cushions, automotive seating

By referencing a foam grade chart, you can match your specific requirements to the foam grade that best suits your needs. This helps ensure that you select the right foam for your project.

Furniture Grade Foam

Furniture grade foam is designed to meet the specific demands of upholstery and cushioning in furniture pieces. It offers a combination of comfort and durability, making it an excellent choice for sofas, chairs, and other seating arrangements.

Key Characteristics of Furniture Grade Foam:

  • Balanced Comfort: Furniture grade foam strikes a balance between comfort and support, providing a comfortable seating experience while maintaining its shape.
  • Longevity: It is engineered to withstand the wear and tear of regular use, ensuring that your furniture remains comfortable and supportive over time.

Common Uses for Furniture Grade Foam:

  • Sofa and Chair Cushions: This type of foam is commonly used for the seat and back cushions of sofas, chairs, and loveseats.
  • Dining Chair Padding: Furniture grade foam can also be used to provide comfortable seating in dining chairs and barstools.
  • Ottomans and Benches: It is ideal for providing padding and comfort in ottomans and benches.
  • Custom Upholstery: Furniture grade foam can be cut and shaped to fit custom upholstery projects, ensuring a perfect fit.

What Is the Highest Density Foam?

The highest density foam available in the market is often referred to as “ultra high-density foam.” This foam is known for its exceptional density and firmness, making it suitable for specialized applications that require extreme durability and support.

Key Characteristics of Ultra High-Density Foam:

  • Exceptional Durability: Ultra high-density foam is designed to withstand extreme wear and tear, making it suitable for heavy-duty applications.
  • Unyielding Support: It offers unparalleled support, making it ideal for situations where maintaining shape and support are paramount.

Common Uses for Ultra High-Density Foam:

  • Healthcare Mattresses: Hospitals and care facilities often use ultra high-density foam in medical mattresses to provide exceptional support and comfort to patients.
  • Industrial Padding: In industrial settings, this foam is used for padding in equipment and machinery to reduce vibration and impact.
  • Specialty Seating: Ultra high-density foam is used in specialized seating for applications like aircraft seating and ergonomic office chairs.

Which Foam Is Best for Sofa

Selecting the best foam for your sofa depends on your preferences and the intended use of the sofa. Here are some factors to consider:

  • Sofa Purpose: Consider how the sofa will be used. If it’s for lounging and relaxation, a softer foam may be preferred. For more formal seating, a firmer foam may be suitable.
  • User Preferences: Take into account the comfort preferences of the individuals who will be using the sofa. Some people prefer softer cushions, while others prefer firmer support.
  • Budget: Your budget may also influence your choice of foam. High-density foam tends to be more durable but may come at a higher cost.
  • Customization: Some foam suppliers offer customization options, allowing you to choose the density and firmness that best suits your needs.


The best foam for your sofa should provide a balance of comfort and support that aligns with your specific requirements and preferences. High-density or furniture-grade foam is often a good choice for sofas, as it offers durability and comfort for everyday use.

Contact our friendly team today to discuss your foam needs.