Anything Foam, here, in our local factory
What we do and how we do it
Once the details of your foam order are confirmed, the project is added to our schedule. Most of our orders are completed in 3-5 days. Keep in mind that this timing can be affected by both the queue of other custom orders and the production needs of the mattress and upholstery departments. The current stock level of foam also affects the lead time. If the foam you selected is low or out of stock, it may take 1-4 weeks to receive before we can resume your project.
Because of these factors, we recommend submitting your custom order at least 2 weeks prior to your deadline. This includes planning recreational vehicle projects between or before any upcoming vacations.
Same-day completion of small projects is available on request with advance notice. We must be contacted at least the night before to be able to guarantee same-day service. For cutting foam or re-stuffing cushions, we must have the dimensions or original covers by 9 am on the day of service. A salesperson will advise you whether it can be completed while you wait, or if it will be completed before 4pm. We will call you as soon as your project is ready to be picked up.
The first thing required to start your order is providing the length, width, and depth of the foam you need. With the dimensions we can calculate the board-feet needed, the price, and estimate the completion date. Simple dimensions are all that’s needed to order rectangular and wedge shapes.
If your project features rounded edges or precise angles, we will require a pattern. The original mattress or cushion can be used as a pattern for recreation. If you do not have an original to create a pattern from, we will need a pattern of the space the foam is going to fill.
To do this, lay out a large sheet of butcher paper, plastic, joined newspapers, or similar material that is slightly bigger than the space you are patterning. Use a marker to trace the perimeter as accurately as you can. Combining this pattern with general dimensions will ensure that the final product is a perfect fit.
If you need assistance with patterning or measuring, please contact us. We can assist you in the showroom or schedule a house-call for a small fee. Please understand that foam is a dynamic material that stretches and compresses when run through the saw. Though we will cut it as accurately as possible, allow for a half-inch tolerance in the final product.
We offer three main types of foam, each with a unique feel and specialty. Selecting the option that best fits your goals or application for the foam is important.
High-Resilience Polyurethane Foam
H.R. Polyfoam is a fully synthetic material that is highly responsive to changes in pressure. It is the material used in most Square Deal mattresses and the most popular choice for fabrication customers. It is open-celled, reasonably breathable, and has a classic bouncy feel. We stock this in two grades, mattress quality and upholstery quality.
Mattress grade foam is less tolerant of concentrated pressure (such as sitting) and is designed to have a more gentle feel when your weight is distributed. This makes it the best choice for custom mattresses, wedges, toppers and camping pads, crafts, cushions in low traffic areas and similar applications. There is only one firmness option available
Upholstery grade polyfoam is a denser option designed to support more pressure and tolerate more wear and tear. This is recommended for high traffic areas, recreational vehicles, all upholstery applications, and firm custom mattresses. The upholstery polyfoam is available in three firmness options; soft, medium, and firm.
Memory Foam
Memory Foam refers to a special kind of polyurethane that has been combined with additives to increase its viscosity and elasticity. This ‘visco-elastic’ foam reacts to sustained pressure by relaxing to conform slowly around the object, and restores itself to shape when pressure is removed as the foam cools and airflow increases. Our open-celled memory foam is infused with copper for an improved experience, directing heat away from the body for consistent comfort. However, its increased elasticity is trickier for our foam saws to cut in layers. Custom memory foam is only available in 2.5 inch thick increments to ensure consistent quality. We recommend memory foam as a bed topper, a primary comfort layer for custom mattresses, and as chair pads for office, home, and travel.
Natural Talalay Latex
Natural Latex is the classic foam rubber – durable, dense, and long-lasting. The Talalay production method of injection molding the natural liquid latex produces a pleasant, springy foam without artificial additives. Its natural composition is cooler than other foams, known to reduce allergens, and has a unique buoyant feel. We recommend Natural Talalay Latex for toppers and mattresses, antique upholstery with original latex, and anyone seeking products that are free of artificial chemicals. We offer three densities of Talalay Latex; soft, medium, and firm.
If you are interested in more details about the foam we offer, please see the Foam Certifications page.
A simple cover goes a long way to protecting your foam and extending its life. Depending on your desired result, you have the option of getting your foam covered by the Mattress department or the Upholstery department.
Most customers have their covers made by the Mattress department. With this option, you have a limited selection that offers utility and comfort, and the lead time of approximately 3-5 days does not change. The covers can be sealed or include a zipper for easy cleaning or replacement. Your fabric options include the following:
- Water-resistant Ventex fabric
- Soft Cotton-poly fabric
- Upholstery Cotton fabric
- Washable Cotton fabric
- 1” Mattress Quilt and Ticking
- 1⁄2” Organic Cotton + Wool Quilt and Ticking
Price for covers will be based on the size and geometric complexity of your foam as well as material chosen. If you had an alternative covering option in mind, the Mattress department is happy to discuss it with you.
The Upholstery department lets you choose upholstery fabrics from any of our vendors, including vinyl and leather. These must be ordered by the yard and take a few weeks to arrive. We also have a limited selection of in-stock fabric to choose from at a discounted price. Your lead time will be determined by the regular Upholstery department schedule. This option is preferred when the foam is used in decorative, permanent, or high-traffic areas. For more information about working with the Upholstery department, please see our Upholstery Process page.
For any style cover you choose, attachments can be added to make your foam easier to store and move. Ties or velcro can be added that allows the foam to be easily rolled. We can create hinges in the foam and cover that allow it to be folded for easier transportation or to accommodate furnishings. Handles are another option that makes your foam easier to install and adjust in place.
Covers are an optional addition to your foam order. You can even receive your foam and return to us later if you decide to add a cover or attachment.
Occasionally, we will have enough foam to complete your order, but not in one continuous piece. To achieve the correct length or width, we may have to laminate two or more pieces together with a chemical bonder. This bonding process is durable and does not significantly affect the wear or comfort, especially if the foam will be inside a cover. Lamination is also used if you are combining layers of foam in different densities. At the time of order, you will be asked to mark whether you consent to receiving laminated foam or require a continuous piece only. If you do not consent to lamination, and there is not enough foam in stock to cut a continuous piece, your project will be put on hold until the new shipment of foam arrives.
Square Deal has been selling custom fabricated foam since 1969. Our experience is that each project holds its own personal significance, so we take special care in our craftsmanship. We look forward to speaking with you soon!