Online cut-to-size foam shop

Home upholstery DIYers, boat and RV owners, small upholsterers, crafters, cosplay makers and small businesses needing packaging or padding.

You sell cut pieces at a price per size and thickness, well above your bulk sheet cost. Extras such as cushion covers, batting and spray adhesive add to each order.

• Accurate measuring and cutting
• Online selling and photography
• Customer service
• Packing and shipping bulky items

• Foam is flammable. Check fire code and insurance requirements for storing it at home or in a unit
• Upholstery foam may need to meet flammability rules in some states, such as California's. Check what applies to what you sell
• Check zoning, home occupation permit and HOA or lease rules if you cut and store stock at home
• Register for a state sales tax permit and ask wholesalers about resale certificates
• Bulky items can have high shipping costs, so test rates before setting prices
• General liability and product liability insurance

Startup costs are typically around $2,000 to $10,000, depending on how much foam stock, cutting equipment and packing supplies you buy. Test shipping rates for bulky items before setting prices, since shipping can affect what you charge.

Check fire code and insurance requirements for storing flammable foam at home or in a unit. Also check whether your state has flammability rules for upholstery foam, plus zoning, home occupation permit, HOA or lease rules, and sales tax permit requirements.

Monthly revenue is typically around $1,000 to $5,000, depending on your product range, pricing and how many orders you can cut and ship. The estimate assumes at least about 10 hours of work a week.