What Is the White Layer on My Cushion Foam? Dacron Wrap Explained

You unzip your new cushion cover and find the foam wrapped in a soft, white, fluffy layer. Some customers assume it's packing material and start to peel it off. Please don't. That layer is Dacron wrap, and it's part of the cushion. Here's what it does, how it affects size and fit, and the questions we get about it most often.

Quick answer: The white layer around your foam is Dacron wrap, a soft polyester fiber batting that covers the foam on all sides. It rounds the edges, fills out the cover so it looks crisp, and makes the top feel a little softer. It isn't packaging, so leave it on. It adds some loft, so a wrapped insert can look bigger than the size you ordered until it's zipped into its cover. The thickness you order is the thickness of the foam.

What Dacron wrap is

Dacron is a polyester fiber. In upholstery, the word is used for the thin sheet of polyester batting wrapped around a foam core before it goes into the cover. On our cushions, the wrap covers the foam from all sides: top, bottom and edges.

It looks a bit like the batting inside a quilt. It's white, light and slightly fluffy, and it's wrapped snugly around the foam so it moves with the insert when you slide it in and out of the cover.

What it does for your cushion

• Rounds the edges. Bare foam has sharp, square corners. The wrap softens them, so the cover looks full and the corners don't look boxy or hollow.
• Fills the cover. A cover sewn to the size of your cushion needs something to press against. The wrap takes up the small spaces between foam and fabric, so the top stays smooth instead of wrinkling.
• Softens the feel. It adds a thin, gentle layer on top of the foam. On firmer foams, that first touch feels a little more comfortable.
• Makes inserting easier. The fiber slides against the inside of the cover more easily than bare foam, which tends to grip the fabric.

"Is this packing material?" The question we get most

When customers write to us about Dacron, it's usually because they weren't expecting it. The most common messages we get are along the lines of "the foam looks like something was just put on for shipping" or "there's a white layer coming loose, should I take it off?"

The answer is always the same: it's meant to be there. If a bit of the wrap has lifted at a corner, smooth it back down against the foam and slide the insert into the cover. The cover holds it in place once it's zipped.

If you remove the wrap, the cushion will still work, but the cover will look looser, the corners will look flatter, and the fit will be a little different from what we sewed the cover for.

Why a wrapped insert can look too big

This is the second question we hear, especially from customers who measure the insert before it goes into the cover. The wrap adds loft. Out of the cover, a wrapped insert can measure larger than the size you ordered, on the edges as well as the top.

That's expected. The size you order is the size of the foam, and the wrap compresses once it's inside the zipped cover. So if you want to check your order, measure the foam itself by pressing the wrap down at the edge, or measure the finished cushion once it's zipped in. Measuring the fluffy, uncompressed wrap will always give you a bigger number.

Foam that has been shipped compressed can also look a little uneven at first while it recovers its shape. Give it time out of the packaging before you judge the size.

How to get a wrapped insert into its cover

A well-fitted cover is snug by design, and the wrap adds a little bulk. These steps make it much easier:

1. Open the zipper all the way and turn the cover so the zipper side faces you.
2. Fold the insert lengthwise (like a taco) so it's narrower than the opening.
3. Push the folded insert into the far end first, then let it open up inside the cover.
4. Work the corners into place one at a time with your hand inside the cover, so the wrap sits flat against each corner.
5. Zip slowly, pressing the foam down just ahead of the zipper. If the zipper strains, stop and adjust the insert instead of forcing it.

For long bench or chaise cushions, a second pair of hands helps. One person holds the cover open, and the other feeds the insert in.

Thickness: what you order vs what you see

The thickness you choose in the builder is the thickness of the foam. Foam comes in whole-inch sheets, so we make 1, 2, 3 inches and so on, not half inches.

Inside the cover, the wrap compresses, so the cushion looks like the size you ordered. It does add a bit of softness and height on top. If your cushion must fit under something, such as a window seat lid that needs to lift or a bench under a window sill, choose the thinner of the two thicknesses you're considering, or ask us about your clearance before you order. Our cushion thickness and foam guide walks through the options.

When you might not want a wrap

Dacron wrap suits most cushions, but there are a few cases where it's worth asking us first:

• You're putting new foam into an existing cover that already fits snugly. The extra loft could make it hard to zip. Measure the old cover seam to seam and tell us it's a tight fit when you order custom-cut foam inserts.
• You're ordering thick outdoor foam. On our thickest quick-drying outdoor cushions, our team may suggest leaving the wrap off so the cushion fits its cover well. We'll advise you on your size.
• You need an exact height. If every fraction of an inch counts, mention it so we can recommend the best combination of foam and wrap.

To see the foam types we cut to size, browse our custom foam.

When we're not the right fit

• We don't sell thin foam toppers to add to an old cushion. If a cushion has gone flat, replacing the foam is the better fix, and you can keep a cover that's still in good shape.
• Tufted, button-pulled cushions aren't something we make. Our covers are zippered and removable.

Frequently asked questions

What is the white fluffy stuff around my cushion foam?

It's Dacron wrap, a layer of polyester fiber batting around the foam. It rounds the edges, fills the cover and adds a little softness. It's part of the cushion, so leave it on.

Should I remove the Dacron wrap before putting the foam in the cover?

No. The cover is sewn to fit the wrapped insert. Without the wrap, the cover can look loose and the corners can look flat.

Why does my foam measure bigger than I ordered?

Because you're measuring the loose wrap, which compresses once it's zipped inside the cover. Press the wrap down to measure the foam, or measure the finished cushion with the cover on.

Does Dacron wrap make the cushion thicker?

The thickness you order is the foam. The wrap adds a little loft and softness on top, but it compresses inside the cover, so the cushion looks the size you ordered.

Can I order foam with or without the wrap?

Most cushions we make include the wrap. If you're ordering foam for a cover you already have and the fit is tight, tell us before you order and we'll advise you.

How do I get the cushion back in the cover after washing?

Fold the insert lengthwise, push it into the far end of the cover, let it open up, then work each corner into place before zipping. Our measuring guide also helps if you're checking sizes.

Sources

• Questions customers send our care team about Dacron wrap, insert fit and thickness, and how we make our cushions.