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Our Cushion Refilling Process

Here we describe the numerous stages we need to go through in order to professionally refill your cushions… you'll see that there's a great deal more expertise needed than just putting a cut piece of foam in your cover and hoping it will look correct!

The majority of customers' cushions we receive require a 'domed' shape to be created in order to correctly fill the cover, and most importantly, STAY correctly filled, long term.

As an example here's the process we go through to create a typical cushion of this type…

We select the correct new block from our vast selection of foams. The huge ¼ tonne block is sliced down to a manageable size!
We carefully cut the correct overall size required for the cushion. If you were having your cushions refilled elsewhere, by just inserting a new cut piece of foam, this would be the end of the process! However, our process continues by specialist angled band knife, which is set up to the correct measurement for the cushion.
Our experienced foam cutter then begins to cut a 'chamfer'. You can see the angled chamfer being carefully cut from the cushion.
All 8 sides of the cushion (i.e. both top AND bottom of the cushion) are now chamfered ready for assembly. A close-up of the shape we have created.
The chamfered top piece is then reversed and added to the flat centre core. These 3 pieces then move on to be bonded. Our specialist high strength adhesive is sprayed onto the components.
We begin assembly of the components. The final piece is carefully bonded into position.
Last part! Extra thick Dacron Wadding is prepared to be applied to the domed cushion.
We apply specialist adhesive to the Wadding, to ensure it stays in place long term. The final piece is applied.
We purposely overlap the sides, to ensure correct fullness of the cover. A final check that everything is correctly bonded.
We always apply a stockinette undercover to protect the Wadding from movement of your cover. Our finished 'domed' cushion, sliced in half to show how taking the care and time to do the job properly, results in a completely filled domed cushion, with no gaps!
This is an example of how most companies would try and 'dome' a cushion. As you can see, it would be very quick and easy to do, with no skill or specialist machinery needed, BUT with gaps that will quickly collapse within weeks of being sat on! You decide… Do you want to spend your money with someone doing the job cheaply (left)… or with our family run company and have it done professionally (right)!
This is how a typical feather/fibre filled seat cushion looks when it arrives with us… Sagged, 'un-plumped' and with no comfort left at all! Our finished domed filling, carefully refitted to its cover. Not only does it look and feel correct now… but it will remain so long term.

Give us a call on Freephone , click here to use our online form, or drop us a line at to find out more, including an approximate quote.
We promise you a friendly, professional response.

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We're an established family-run business with very experienced long-term staff
We collect your cushions from your home and these are safely delivered to our premises…
Your cushions and covers arrive…
Are carefully unpacked…
Expertly assessed and measured
From our vast stock of high quality cushion fillings…
Our 11 stage process begins
Then after we've professionally refilled your cushions…
They're securely packaged up and on their way back to you!
 If you're local, we have a permanent Showroom...
With many options to offer…
For you to try out and select for your choice of comfort!
We can refill leather furniture cushions…
…as well as fabric!
No job too big…
…or small!

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The Cushion Refilling Co. is a trading style of Bristol Upholstery and Soft Furnishings Co., which is in turn owned by The Caravan Seat Cover Centre Ltd. E. & O.E.
Our business is an independent family run company and we are not, and do not claim to be, connected to the original Ercol Company in any way.