How to Make Homemade Cut to Size Padding

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I love doing odd jobs around the house, and making things for our home that everyone can enjoy. Our bedroom, for example, is filled with little projects I’ve made over the years. There’s a new headboard, some throw pillows, and even a custom-cut foam mattress topper (which I’ll talk more about later).

There are a lot of different kinds of foam and foam padding out there, from the standard foam blocks to custom foam pillow inserts. You can order custom foam cushions or foam replacement cushions for benches and chairs, but what about when you want to make a project for which you need custom cushion sizes? Here’s how to make your own DIY cut to size padding.

Foam is used in many different products. It’s a popular choice for cushioning and padding, whether you’re making a couch or mattress, or just want your chair cushions to be extra-comfortable. Foam can be cut to size, and you can use it as a foundation layer beneath other materials like fabric or leather.

In this tutorial, we’ll show you how to make your own DIY cut-to-size foam padding using scraps of high density polyurethane (HDPE). This type of foam costs less than other types of commercial options such as memory foam but still provides good support because it’s firm yet soft enough to conform around body shapes when squeezed together with another piece of HDPE.*

To create custom shapes with this material:

1st) Measure out the dimensions needed for each individual piece (or multiple pieces) of padding that will fit into the final object after assembly; 2nd) Cut those pieces out; 3rd) Glue them together with spray adhesive if necessary (using enough glue so that no gaps are visible between surfaces); 4th) Trim off any excess material; 5th) Sand down any sharp edges left behind from trimming down excess parts after gluing pieces together.*

What you’ll need for your DIY cut to size padding

In addition to the foam padding, you’ll need a ruler, marker and cutting board. A pencil will come in handy when drawing your pattern on the pad. You might also want to protect your work surface with newspaper so that it doesn’t get dirty or stained (just be sure not to use any paper that has had an image printed on it).

Before you start cutting, make sure you understand where each piece of foam needs to go. If possible, try sketching out a rough diagram of how everything should fit together before moving forward with any cuts at all. This will allow for maximum accuracy as well as help keep things straight during assembly and finish off later down the road if needed.

How to choose the right kind of foam for your project

If you’re starting from scratch, you’ll need to choose the right kind of foam for your project. This can be a daunting task when there are so many types out there! Here are some things to keep in mind while shopping:

  • Consider density. If you’re making a cushion or pillow, choose a low-density foam that will provide support and comfort. If you’re using it as padding for something like a wall or table top, then high-density is better because it won’t compress as much over time.
  • Size up your available space when measuring the size of your foam block; don’t just assume that all cut-to-size pads are equal! One brand may fit your needs better than another depending on how much room there is between joists underneath flooring materials (more on this later). It’s easy enough to experiment with different brands until one feels perfect; just remember that cutting into any type means more waste than buying new rolls every time—so try not to overdo it!

Cut the foam by hand or use an electric knife

  • Cut foam by hand. You can use an electric knife to cut foam, but it’s not always easy to get a clean cut. An electric knife is also very loud and tends to leave small pieces of foam on the edges of your project. If you’re using a sharp craft knife, make sure you have a few extra blades on hand in case one dulls before you finish cutting all of your foam pieces.
  • Cut foam with an electric carving knife or serrated bread knife instead of a standard utility blade as they tend to keep their edge longer than most other types of knives will do so with regular use (though there are exceptions). These types also tend not leave any slivers behind while still making clean cuts through thick layers such as those found in pillows and seat cushions among other things like these

Remember that you can always make it smaller

If you’ve read all the way through this blog, you may have noticed that we started with a foam roll that was 4′ wide and cut a strip from it. This means that our padding will be 3″ thick. However, if we were to put these pads into a chair or sofa cushion and measure them, they would be smaller than the dimensions of the furniture itself (specifically because of seam allowance).

So what do we do? In cases like this one where our measurements are off by an inch or two either way, I like to just go ahead and glue them together in order to make sure everything fits nicely into its container. When you’re gluing multiple strips together at once in order, it’s often helpful to number all your strips so they stay organized while drying overnight (or longer).

Most craftsmen will tell you that it’s better to cut something too big and then cut down than it is to cut something too small and have to glue more on.

One thing that most craftsmen will tell you is that it’s better to cut something too big and then cut down, than it is to cut something too small and have to glue more on.

The reason for this is simple: cutting it too small means you have more work ahead of you. You have to trim the foam, sanding away at it until the shape looks just right. If you accidentally make a mistake when trimming down your foam padding, it might mean having to start over from scratch. The only way around this problem is if the shape itself matches exactly what’s in your head; thus necessitating exorbitant amounts of planning and measuring ahead of time (or spending more money).

Cutting it bigger means no trimming required; just spray glue on and stick them together!


As you can see from this guide, making your own DIY cut to size padding is easy. You don’t need any special equipment or skills to make DIY cut to size padding for whatever project you have in mind! Whether it’s a custom cushion for an old chair or just an extra layer of comfort on your bed, the best thing about homemade padding is that it fits exactly what you need and where you need it. By following these instructions, you’ll be able to create perfect cuts every time.

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