Custom Cut Mattress Inserts

Sleep on a mattress that actually fits with Custom Cut Mattress Inserts. These foam mattresses are cut to your exact dimensions, which helps with RV bunks, boat berths, daybeds, trundle beds, and odd-sized antique frames. Choose the foam that suits how you sleep, from medium-feel High Density to firmer Luxury, and add a Dacron wrap for a little extra softness. The right combination gives you cushioning on top and support underneath for a good night's rest. Send us your measurements, including any angled or rounded corners, and we will cut a custom mattress to order.

Custom foam mattress for any bed

Need foam for a mattress that isn't a standard size? We cut a custom foam mattress from one solid block (up to 6″) or two bonded layers (up to 8″), so it fits the frame instead of the other way round.

• RV and camper mattresses: short queens, bunks and dinette beds, including clipped or rounded corners.
• Boat mattresses: V-berths and cabin bunks cut from your template. Choose Dry Fast foam for berths that get damp.
• Daybed and trundle mattresses: a firm, even surface for sitting by day and sleeping at night.
• Antique and custom frames: spool beds, built-in bunks, window beds and anything an off-the-shelf mattress won't fit.

Common mattress sizes

These are typical sizes only. Always measure your frame or old mattress, since RV, boat and antique beds often differ by an inch or more.

Choosing your foam

• High Density: a medium feel for everyday seats, chairs and mattresses. 1.8 lb/ft³ density, 35 lb ILD, lasts about 7 years. For thin dining seats (1″–2″), Luxury foam holds up better.
• Luxury: firm, and firmer as it gets thicker (7″–8″ feels very firm unless you weigh over 200 lb). 1.8 lb/ft³, 50 lb ILD, lasts about 5–8 years. A good pick for dining seats from 1″ to 3″.
• Dry Fast: open-cell outdoor foam that lets water drain straight through, for patio, pool and boat cushions. Firm, 1.8 lb/ft³, 60 lb ILD, lasts about 5–8 years.
• Super Soft: for sofa back cushions and mattress toppers only, not seats. 1.2 lb/ft³, 12 lb ILD, lasts about 5 years.
• Dacron wrap (optional): a 1″ layer of polyester fibrefill around the foam that rounds the edges and fills the cover. We attach it with fine staples that won't tear the foam or the cover.

Entering your size

• Enter every measurement in inches.
• Sizes between quarter inches are rounded up to the next ¼″.
• Give us the finished cushion size. If you add a Dacron wrap, don't make the numbers smaller; we allow for the wrap.

Thick cushions

We cut foam up to 6″ thick from one solid piece. From over 6″ to 8″, we glue two layers of the same foam together at no extra charge. For anything over 8″, or to mix two foam types in one cushion, contact us for a quote.

Manufacturing Tolerances

Every piece is cut to within ±0.5″ of your measurements. Most orders ship in 2–3 weeks.

Questions about custom foam mattresses

What foam is best for a mattress?

High Density gives a medium feel that suits most sleepers. Choose Luxury for a firmer bed, and add a Dacron wrap for a softer top. For a boat berth that can get damp, choose Dry Fast.

How thick should a foam mattress be?

4″ to 6″ suits bunks, daybeds and trundles. For a main bed, 6″ to 8″ gives more support. We cut up to 8″; for thicker, contact us for a quote.

Can you cut angled or rounded corners?

Yes. Send the measurements of each side, or a paper template for curved V-berths and RV corners, and we cut the foam to match.

Does the mattress come with a cover?

This listing is foam only. For a zippered cover, see custom cushion covers, or browse all custom cut foam.