Is your sun lounger looking saggy and feeling uncomfortable? You can fix that problem quickly and easily with F.C. Hancox’s sun lounger foam cut to size.

If your sun lounger mattress has seen better days but the lounger itself is still fine, we stock a variety of quality foams perfect for rejuvenating sun lounger cushions and mattresses. And with foam cut to size, you can replace worn foam with a foam type that is perfect for you, without the cost of buying new.

Whether you need foam for a traditional garden sun lounger, a luxury daybed or a reclining patio lounger, we’ll cut the quality foam of your choice to your exact measurements.

All our foams are manufactured in the UK and cut to size by our experienced technicians here at our South Coast warehouse.

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Why Choose F.C. Hancox?

F.C. Hancox is a family firm that has been working in the upholstery trade since 1960. We supply a wide variety of foams suitable for all kinds of projects to commercial and domestic customers alike.

Our foam-cut-to-size service ensures that our customers get just the right foam for their project cut to the exact shape and size they asked for.

If you are looking for sun lounger foam cut to size, we’ll have the perfect foam for you.

We offer:

✓ Foam cut to your exact measurements

✓ Premium UK manufactured foam

✓ Wide choice of foams, including outdoor foam

✓ Cut in-house by our own staff – no outsourcing

✓ Trade prices for online orders

✓ Fast UK delivery by our own drivers

✓ Expert advice just a call away

It’s so easy to order your sun lounger foam online, just head for our foam-cut-to size page and follow the easy steps. If you need help or advice our friendly staff are only a call away.

Order Sun Lounger Foam

How to Order Sun Lounger Foam

Replacing your sun lounger foam couldn’t be easier. On our foam cut to size home page:

Step 1 – Choose the shape nearest to the foam pad you need.

Step 2 – Enter your measurements using the guide on the shape. You can use inches or centimetres.

Step 3 – Choose your foam. Here you will get an instant quote.

Step 4 – Select optional extras including polyester wrap and stockinette

Step 5 – Complete your order.

Your order will go to our warehouse to be cut to the size and shape you requested. Once cut, your new sun lounger foam will be despatched using our own delivery service.

TIP: Take a look at our foams before you start and choose the one you want. You can find out more about our foams here, Foam Types or read on for information about our recommended foams for sun loungers.

What Is the Best Foam for a Sun Lounger?

Choosing the right foam depends on how your sun lounger is used, where it’s stored and the level of comfort you’re looking for.

For most domestic garden furniture, we recommend Reflex 400H, which offers excellent comfort, durability and resilience. It provides outstanding support while retaining its shape for many years.

This is an indoor grade, so your sun lounger cushion or mattress will need to be brought inside when wet and stored away when not in use.

Customers looking for a more economical solution often choose CMF38 Blue, providing excellent, firm support with a long-lasting performance at a lower cost. Another choice, that matches a lower budget is SF33/190.

If your sun lounger remains outdoors throughout the year or is regularly exposed to rain, a reticulated foam will be the best choice. Reticulated foam has an open-cell structure that allows water to drain away quickly. The brand of reticulated foam sold by F.C. Hancox is called Calipore Outdoor Foam.

Our Recommended Sun Lounger Foams

Different foams provide different levels of comfort, firmness and durability. One of the benefits of having foam-cut-to-size is that you can choose the foam that suits you rather than having a standard one-type-fits-all cushion or mattress. Whilst we have many foams to choose from, these are the ones we recommend for sun loungers:

Foam Grade	Best For
Reflex 400H	Premium comfort and everyday use
CMF38	Excellent value with firm support
SF33/190	Budget-conscious projects
Calipore Reticulated Foam	Outdoor furniture exposed to moisture

Reflex 400H – One of four Reflex grades that we sell, Reflex 400H is a premium high-resilience foam that provides outstanding comfort while maintaining excellent support. It is called Reflex because it adapts to the body’s shape in use then regains its shape after use.

Ideal for:

• Garden sun loungers
• Premium outdoor furniture
• Luxury daybeds
• Hotels
• Holiday homes
• Regular daily use

CMF38 – CMF38 is a quality firm foam that has excellent durability, so it provides fantastic value for customers wanting supportive seating without moving into premium foam grades.

SF33/190 – A firmer budget option to CMF 38, offering great value for money for anyone wanting supportive seating which is economical.

CMF38 and SF33/190 are Ideal for:

• Garden furniture
• Patio loungers
• Replacement cushions
• Everyday use

Calipore Reticulated Foam – Unlike standard foam, reticulated foam is specifically designed for permanent outdoor environments. If your cushions are to remain outdoors throughout the year, then choosing a reticulated foam offers significant advantages. The brand of reticulated foam that we sell is called Calipore outdoor foam.

Unlike traditional foam, Calipore reticulated foam has an open-cell structure that allows water to drain straight through rather than being absorbed.

Benefits of outdoor foam like Calipore include:

• Quick drying
• Excellent drainage
• Reduced moisture retention
• Suitable for exposed outdoor furniture
• Ideal around swimming pools
• Excellent for hotels and spas
• Antibacterial properties to prevent mould and fungus

Outdoor Foam vs Indoor Foam

You can use indoor foam outside. It is no different to the cushions that you have on your sofa or armchairs. Whilst indoor foam works exceptionally well inside the home it can deteriorate much faster when constantly exposed to moisture and changing weather conditions if left outside.

Outdoor foams such as Calipore have been specially designed to cope with wet and damp conditions. The best way to compare them is indoor foam looks like a sponge; its cells are closed so will keep in moisture for longer. Outdoor foam is more like mesh, or net, so moisture can pass through easily allowing it to dry quicker than indoor foam.

As well as garden furniture and sun loungers, outdoor foams are used in the marine industries for items such as boat cushions.

Standard Foam	Outdoor Reticulated Foam
Comfortable	Comfortable
Excellent support	Excellent support
Holds water	Allows water to drain through
Slower drying	Fast drying
Suitable for occasional outdoor use	Designed for permanent outdoor use

Sun lounger foam made of a reticulated foam like Calipore can be left outside even in a shower of rain, whereas an indoor foam will need to be brought in out of the rain. Choosing the correct foam will help maximise the lifespan of your new sun lounger foam.

Why Replace Your Sun Lounger Foam?

Some people replace their entire sun lounger simply because the cushion has become uncomfortable. More often, it is the foam that has deteriorated while the outer cover remains perfectly serviceable.

Replacing the foam is often a far more economical solution than purchasing a completely new sun lounger.

New foam will:

• Restore comfort
• Improve support
• Help relieve pressure points
• Improve appearance
• Extend the life of your furniture
• Reduce waste
• Save money

If your existing cushion covers are still in good condition, replacing only the foam can completely transform the feel of your sun lounger.

Why Does Sun Lounger Foam Deteriorate?

Outdoor furniture experiences much harsher conditions than indoor seating.

Throughout the year your foam is exposed to:

• UV sunlight
• Rain
• Morning dew*
• Heat
• Temperature changes
• Moisture*
• Regular body weight

*This is especially the case if the foam is not an outdoor foam.

Over time these conditions gradually break down the foam cells, causing the cushion to lose its shape and support.

Signs your foam needs replacing include:

• Flat cushions
• Sagging areas
• Lack of support
• Foam crumbling
• Uneven seating
• Feeling the frame underneath

You can read more about this here: Signs Your Outdoor Foam Needs Replacing

Replacing the foam restores the comfort of your sun lounger without replacing the furniture itself. It also provides an opportunity for you to personalise the foam making your sun lounger’s comfort be exactly what you want.

What Thickness Foam Should I Choose?

If you are replacing the foam in an existing sun lounger cushion or mattress, the thickness will depend on the size of the cover. You will use the cover to measure for your new foam.

If you are making a new mattress or cushion, you can choose a new, thicker or thinner cover.

The ideal thickness depends on your preferred comfort level. As a general guide:

40-50mm – Suitable for thinner contemporary loungers and lightweight furniture.

75mm – One of the most popular thicknesses, providing an excellent balance of comfort and support.

100mm – Ideal where maximum comfort is required or for luxury garden furniture.

125mm and above – Commonly used on premium outdoor daybeds and high-end commercial furniture.

If you’re unsure about what thickness to choose, our team can recommend the most suitable size before you order. Simply get in touch, by calling 01202 486956 or filling in one of our conatct forms and we’d be happy to help.

Why Foam Density Matters

It’s easy to assume that thicker foam means greater comfort, however, density and firmness are both something to consider when choosing the best foam for your sun lounger.

The density of a foam is not about how firm the foam is but how strong it is.  The density of a foam affects how it feels and how the foam will perform when it’s used. A denser foam is supportive, which is why memory and reflex foams are dense foams. https://www.fchancoxfoam.co.uk/high-density-foam/ 

Our experienced staff are happy to explain the density of all our foams and what would be best for your situation. Once you know the best foam to use, then you can order it through our foam cut to size service.

Can We Cut Sun Lounger Foam to Any Size?

Absolutely. Every piece of sun lounger foam we sell is cut to your exact measurements, ensuring a perfect fit within your existing cushion covers or furniture frame.

Whether you need a simple rectangular cushion or a completely bespoke design, our state-of-the -art cutting equipment enables us to produce foam for almost any shape or size.

We regularly cut foam for:

• Standard rectangular sun loungers
• Reclining garden loungers
• Hinged sun loungers
• Luxury outdoor daybeds
• Curved loungers
• Garden cushion foam
• Bespoke commercial furniture

If your existing foam has an unusual profile or shape, simply measure your current cushion or use it as a template and we’ll to enable us to cut an  accurate replacement.

Replacement Foam for Hinged Sun Loungers

Many modern sun loungers include adjustable backrests that allow you to sit upright or recline fully.

These loungers often use hinged foam cushions, enabling the cushion to flex naturally as the frame moves.

F.C. Hancox’s foam cut to size service can supply replacement foam for:

• Single hinge loungers
• Two-piece loungers
• Three-piece loungers
• Reclining backrests
• Folding sun loungers
• Adjustable garden furniture

Every section is cut individually to ensure the cushion folds naturally whilst maintaining comfort across the entire lounger. If you need help ordering this combination of foam, do get in touch, we’re happy to help.

Foam for Luxury Outdoor Daybeds

Large outdoor daybeds have become increasingly popular in modern gardens, hotels, holiday parks and spas.

Because these cushions are significantly larger than traditional garden furniture, selecting the correct foam becomes even more important.

We regularly supply foam for:

• Circular daybeds
• Modular daybeds
• Rattan daybeds
• Outdoor sofas
• Poolside daybeds
• Roof terrace seating
• Luxury garden furniture

For most luxury daybeds we recommend premium Reflex foam, providing exceptional comfort whilst maintaining excellent shape retention.

For permanently exposed outdoor furniture our Calipore outdoor reticulated foam may be the better choice due to its moisture resistant properties.

Commercial Sun Lounger Foam

F.C. Hancox supplies quality replacement foam for commercial customers throughout the UK.

Industries supplied include:

• Hotels
• Holiday parks
• Holiday cottages
• Spa resorts
• Swimming pools
• Leisure centres
• Restaurants
• Care homes

Replacing worn foam is often significantly more cost-effective than replacing complete outdoor furniture, helping businesses to refresh their seating whilst reducing costs.

Trade enquiries are always welcome; simply give us a call on 01202 486956, drop us an email info@fchancoxfoam.co.uk or send a message here: Contact F.C. Hancox Foam – The Leading Foam Cut to Size Specialists.

Why Choose Foam Cut to Size?

With F.C. Hancox’s foam cut to size service, every piece of foam supplied is cut to the exact shape and measurements that you provide and in a foam of your choice. The benefits of choosing foam cut to size are:

✔ Exact fit

✔ Maximum comfort

✔A foam of your comfort choice

✔ Longer lifespan

✔ Less waste

✔ Better value than replacing furniture

You can rejuvenate tired old sun lounger cushions and mattresses with foam that matches your individual needs, quickly and easily. Whatever the reason, custom-cut foam provides a far superior solution than buying standard cushions.

F.C. Hancox sells foams manufactured in the UK cut to the customers exact instructions, in-house by our own experienced technicians. We even have our own delivery service, ensuring that you new foam is delivered to your door.

Can I Keep My Existing Cushion Covers?

If your cushion covers remain in good condition, and the foam can easily be removed, replacing only the foam can completely transform the comfort and appearance of your furniture.

This approach offers several advantages.

It is:

• considerably cheaper than buying new cushions
• environmentally friendly
• quicker than replacing furniture
• ideal for high-quality outdoor fabrics
• perfect for discontinued furniture ranges

Simply remove your existing foam, measure the cover carefully and order replacement foam cut to the same size.

It’s quick and straightforward. Simply go to the foam-cut-to-size page and follow the easy instructions. You can choose the foam which best suits you and add comfort with polyester wrap too. If you are unsure about any part of ordering your new sun lounger foam, then get in touch, we want your complete satisfaction.

Measuring Sun Lounger Foam

Accurate measurements help to ensure your replacement foam fits perfectly.

For the best results use the existing cover. Remove the foam from the cushion cover and measure between the seam lines. Measure:

• Length
• Width
• Thickness

You can use inches or centimetres, whichever you’re most comfortable with.

Bespoke shapes

Not every sun lounger is a standard shape, but we can cut foam to any size or shape. Firstly, on our foam-cut-to-size page, look for the shape nearest to the shape of your cushion. When you click on the shape, you’ll see a diagram which shows you where to take measurements.

For help with measuring for your new foam see: How to Measure Foam.

For unusual shapes we recommend creating a paper or cardboard template or contacting our team before ordering.

If you’re at all unsure about measuring F.C. Hancox’s friendly staff are always happy to advise.

Optional Extras

To improve the finished appearance of your cushions we also offer optional finishing services.

Polyester wrap

Adding a polyester wrap creates a softer, fuller appearance while helping to fill the cushion cover more effectively.

Benefits include:

• smoother appearance
• improved comfort
• softer edges
• premium finish

Stockinette

Stockinette is an inexpensive addition that makes fitting foam into cushion covers significantly easier by reducing friction. It also helps to protect the foam during installation.

You can find out more here: Polyester Wrap & Stockinette.

Caring for Your New Sun Lounger Foam

Although premium foam is designed to provide many years of comfort, a little care can significantly extend its lifespan.

We recommend:

• storing cushions indoors during winter
• allowing cushions to dry thoroughly after heavy rain
• regularly cleaning cushion covers
• avoiding prolonged standing water
• rotating cushions where possible
• replacing damaged covers to protect the foam

These simple steps will help to keep your cushions looking and performing their best for many years.

Why Choose F.C. Hancox?

For more than 60 years, F.C. Hancox has been supplying premium foam products to customers throughout the UK.

We supply quality, UK manufactured foam that is cut by our own technicians here in our south coast warehouse. Using the most up-to-date cutting technology we cut to the exact shape and size you order.

When you order from F.C. Hancox you’ll benefit from:

• Premium UK manufactured foam
• Precision cut-to-size service
• Expert advice before ordering
• Extensive range of foam grades
• Fast nationwide delivery by our own drivers
• Competitive pricing, with trade prices for online orders
• Family-run business with decades of experience
• Thousands of satisfied customers

Whether you’re replacing a single garden cushion or refurbishing an entire hotel terrace, we’re here to help you choose the right foam.

Frequently Asked Questions About Sun Lounger Foam

What is the best foam for a sun lounger?

For most domestic sun loungers, we recommend Reflex 400H. It offers an excellent balance of comfort, support and durability, making it ideal for regular outdoor use. Where furniture remains outside throughout the year, a reticulated foam, such as our Calipore outdoor foam, is often the preferred choice due to its drainage properties.

Can sun lounger foam be cut to size?

Yes. Every piece of foam supplied by F.C. Hancox is cut to the exact measurements provided by the customer, ensuring a precise fit for existing cushion covers or furniture. Simply head for the foam-cut-to-size page and follow the easy instructions.

What thickness foam is best for a sun lounger?

Most sun loungers use foam between 50mm and 100mm, however, the ideal thickness depends on your furniture design, the size of existing cushion covers and the level of comfort you require. When you use our foam-cut-to-size service, you can have the comfort of your choice by selecting the best foam for your personal comfort.

Can I replace just the foam?

Yes. This is the benefit of foam cut to size. If your cushion covers remain in good condition, replacing only the foam is often far more economical than buying completely new cushions.  Simply remove the old foam and measure the size of foam piece that you need using the cover.  Our easy order method can be followed on our foam cut to size page.

Is outdoor foam waterproof?

Traditional upholstery foam is not waterproof. However, a reticulated foam like Calipore has an open-cell construction that allows water to drain quickly, making it ideal for permanently exposed outdoor furniture.

How long should sun lounger foam last?

A high-quality foam can last many years depending on usage, weather exposure and maintenance. Premium grades generally retain their comfort and support considerably longer than lower-density foams.

Can you cut foam for hinged sun loungers?

Yes. We regularly supply foam cut for folding, reclining and multi-section sun loungers, ensuring each section fits accurately whilst allowing the furniture to operate correctly. Our staff are on hand should you need help ordering this combination of foam pieces.

What is Reticulated Foam?

Reticulated Foam is a specialist outdoor foam designed with an open-cell structure that allows rainwater to drain through freely. It dries much faster than conventional upholstery foam and is ideal for poolside or permanently exposed furniture. The reticulated foam supplied by F.C. Hancox is called Calipore. These foams also have antibacterial additives to prevent mould and fungal growth.

Can I use memory foam outdoors?

Memory foam is a luxury foam that would need to be brought indoors after use. It is a dense foam that would take a lot of time to dry if it got wet. We would usually suggest that a memory foam layer is laminated (adhered) to another foam for seating. We do recommend memory foam as a mattress topper, so that could be an option if you would like to have a roll-up option that can be lain on top of your sun lounger and taken indoors after use.

Do you supply foam for hotels and commercial projects?

Yes. We regularly supply foam to hotels, holiday parks, leisure centres, spas, restaurants and other commercial customers throughout the UK.

How accurate should my measurements be?

We recommend measuring as accurately as possible in millimetres. Accurate measurements help to ensure your replacement foam fits perfectly within your existing cushion covers. You can get help with measurements on our How to Measure Foam page

Can I contact someone before ordering?

Of course. If you’re unsure which foam is best, need advice on measuring, or any aspect of ordering foam cut to size, our experienced team will be happy to help before you place your order.  There are several ways to contact our team. Visit our contact page for the best option for you.