How to Shape Foam & Pattern Complex Curves for Sewing
In this video tutorial, we’ll show you how to shape a block of foam into the exact curved shape you need. Achieving a precise shape can be difficult, and we’ll show you our best methods for success. Next, we’ll show you how to take that curved piece of foam and pattern it for upholstery and sewing purposes. We’re using an automotive headrest for our demonstration, but these techniques apply to any contoured foam upholstery application.
Intro - 0:00
Cutting Foam to General Size - 0:41
Shaping Foam - 11:39
Marking Foam for Templating - 17:51
Patterning Newly Contoured Foam - 22:05
Transferring Patterns to Fabric & Cutting - 36:37
Sewing Sides to Middle Panel - 41:40
Tack Stitch End Panels - 48:11
Installing Zipper - 54:19
Sewing Final Stitch on End Panels - 59:56
Inserting Foam - 1:04:49
Materials & Tools List - 1:09:29
MATERIAL LIST:
CushionRite™ Premium Antimicrobial Foam (Firm) - SKU: 124236 https://www.sailrite.com/Foam-and-Pil...
Dura-Skrim® Patterning Material 74" - SKU: 103134 https://www.sailrite.com/Dura-Skrim-2...
EverSoft™ Indoor/Outdoor Denim 54" Vinyl Fabric - SKU: 122216 https://www.sailrite.com/Fabrics/Mari...
Seamstick 1/4" Basting Tape for Canvas & Upholstery (36 yds.) - SKU: 122065 https://www.sailrite.com/Seamstick-1-...
Lenzip® #5 Black Continuous Coil Zipper Chain - SKU: 124596 https://www.sailrite.com/Lenzip-5-Bla...
Lenzip® #5 Black Style A Single Locking Zipper Pull (Coil Chain) - SKU: 124600 https://www.sailrite.com/Lenzip-5-Bla...
Polyester Fiberfill 15 Denier - Hollow Slick Conjugate - SKU: 104467 https://www.sailrite.com/Polyester-Fi...
TOOLS LIST:
Clear Acrylic Ruler 6" x 24" - SKU: 102400 https://www.sailrite.com/Clear-Acryli...
Sailrite® Blade Foam Saw V2 with Carrying Case (110V) - SKU: 121244 https://www.sailrite.com/Sailrite-Bla...
3M™ Super 77™ Spray Adhesive Low VOC 18 oz. - SKU: 636100 https://www.sailrite.com/3M-Super-77-...
Gingher® Scissors Right Hand Lightweight 8" - SKU: 101017 https://www.sailrite.com/Gingher-Scis...
Sailrite® Foam Shaper - SKU: 123583 https://www.sailrite.com/Sailrite-Foa...
Scribe-All® Black Marking Pencil for Vinyl - SKU: 121977 https://www.sailrite.com/Scribe-All-W...
Fabric Edge Pattern Notching Tool - SKU: 124326 https://www.sailrite.com/Fabric-Edge-...
Deluxe 5-1/2" Magnetic Sewing Guide - SKU: 103597 https://www.sailrite.com/Deluxe-5-1-2...
Sailrite® Ultrafeed® LSZ Walking Foot Sewing Machine (110V) - SKU: 311602 https://www.sailrite.com/Sailrite-Ult...
Fabric Edge Match Pliers - SKU: 123498 https://www.sailrite.com/Fabric-Edge-...
Basic Thread Snips - SKU: 123222 https://www.sailrite.com/Basic-Thread...
Sailrite® Ultrafeed® Industrial Sewing Table - SKU: 120934 https://www.sailrite.com/Sailrite-Ult...
Tape Measure 120" - SKU: 102986 https://www.sailrite.com/Tape-Measure...