PU Foam Cutting

We cut PU foam from flat sheets for cushions, pads, packaging inserts, sound control and protective components. Digital knife and CNC cutting for polyurethane foam sheets up to 3000mm x 1500mm – tuned for clean edges, consistent shapes and repeatable nesting.

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Flat parts only — no folding Typical sheet up to 3000 × 1500 mm 1–5 days dispatch

Where PU foam makes sense

PU (polyurethane) foam is the workhorse material when you need comfort, cushioning or lightweight bulk with a soft feel. We mostly cut PU foam for:

Upholstery & Seating Cushions
Comfort foam for furniture and seating applications.

Office, Hospitality & Commercial Fit-outs
Commercial grade foam for office and hospitality interiors.

Mattress Toppers & Overlay Components
Comfort layers for mattresses and bedding products.

Protective Packaging & Box Inserts
Cushioning foam for product protection and packaging.

Fitness, Sports & Medical Padding
Padding for sports equipment and medical applications.

Automotive & Transport Seating Pads
Seating comfort foam for transport and automotive use.

Acoustic & Sound-Control Elements
Sound dampening foam where PU is specified.

Display, Exhibition & Event Builds
Lightweight foam for displays and temporary structures.

General Industrial Pads, Spacers & Linings
Industrial foam components for various applications.

Prototype Work
Prototyping ahead of moulded parts and production.

PU foam characteristics

PU foam is an open-cell material with a softer feel and different behaviour to closed-cell foams like EVA. It can compress significantly under the blade, edges can feather if not supported and the foam can deform if handled incorrectly. We set cutting method, tooling and parameters specifically for the grade and density of PU foam used on your project.

Flat PU foam sheets up to 3000mm x 1500mm

Material properties

Open-cell structure, soft feel and good comfort for seating and pads.
Available in a wide range of densities and firmness levels.
Can be supplied as plain foam sheets or laminated to fabrics and films.

Best cutting methods

Digital knife cutting for accurate 2D profiles and shapes.
CNC cutting for thicker blocks and specialty shapes within our flat cutting envelope.
Carefully tuned speeds and tool paths to minimise distortion and feathering.

For PU foam we favour knife and CNC methods rather than laser, to avoid discolouration and fumes associated with burning polyurethane.

Thickness & formats

Typical thicknesses from 10mm through to 100mm+ (laminated thicker where required).
Flat sheets up to 3000mm x 1500mm inside our cutting envelope.
We can cut your supplied PU foam or help specify common grades.

PU Foam Cutting Capabilities

Accuracy, Nesting & Sheet Size

Digital knife tables tuned for foam and soft material cutting.
Sheets up to 3000mm x 1500mm, nested for best material utilisation.
Controlled compression and hold-down to keep shapes consistent.
Good repeatability across batches and repeat orders.

We can work from CAD, diagrams, templates or existing PU foam parts that need to be replicated or updated.

Edge Quality, Finishing & Kitting

Smooth knife-cut edges with minimised feathering and tearing.
Consistent thickness and profile across matched sets of cushions or pads.
Logical grouping and labelling of parts by room, project area or kit ID.
Packing that keeps foam parts clean, dry and easy to identify on-site.

Our goal is to deliver PU foam parts in a format that lets your upholsterers, joiners and installers move straight into fit-out and assembly.

Why specify PU foam with Laser Cutting Experts

Foam-first cutting approach

PU foam does not behave like rigid sheet – it compresses, stretches and can be easily damaged. Our cutting workflow is set up specifically for foams, with tooling, feeds and handling tuned to keep shapes consistent from piece to piece.

Comfort, fit & appearance in mind

We think beyond the flat pattern and consider how PU foam will feel and look once upholstered or installed. Depth, bevels and edge shapes can be planned to support the finish you are aiming for.

Comfortable with mixed-material builds

PU foam is often used with fabrics, vinyls, plywood and metals. Because we also cut sheet materials in-house, we can help make sure foam parts line up cleanly with substrates and frames.

Trade-friendly for upholsterers & fabricators

We frequently work behind the scenes for upholsterers, joiners, fit-out contractors and OEMs. Clear communication, predictable turnaround and consistent parts are the focus, not chasing your end clients.

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1–5 days dispatch Australia-wide delivery Pickup: Botany NSW

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Simple plates and brackets can often be drawn and quoted the same day.