Latex Foam, a Healthier and More Sustainable Option

The subject of latex foam came up recently when my client that I was creating custom banquette cushions for asked me if there are any options for materials that would be better for the environment. I answered that yes, latex foam is an option. What I knew about latex foam was that it’s a healthier option for people who suffer from chemical sensitivities and also that it is environmentally friendlier than its petroleum based counterpart. I have been thinking about looking into it as an option to offer clients eventually so here was my opportunity. Time to learn something new.

Of course not having worked with it before, I had some questions and so did my client. Mine were more on the how to handle side. Things like allowances for stuffing the cushion and how does the firmness and density compare. Also what about those crazy holes, how do I deal with that? To be totally transparent my biggest concern was cost. I only had one client asking for it and it is significantly more than polyurethane foam. If I made an error in ordering or cutting there was no other job to use it on. I'd be stuck with it. (Hey but my dogs would have the nicest beds around).

After working with it I realized I made it into a bigger deal than it needed to be. It’s harder to source but ultimately it’s really not that different to work with. Here are some of the questions that came up and my answers.

what are the differences between latex foam and "regular" foam?

Latex foam is a natural material derived from the sap of rubber trees. The sap is extracted (think maple syrup)  without harming the tree and processed to form a dense foam material. 

Polyurethane foam (I'm calling this regular since it's the most commonly used) is made by reacting di‐isocyanates and polyols. Both of these products are derived from crude oil. It has a tendency to off-gas.

Note: Something to be aware of is that some retailers sell a synthetic latex or a blend of natural and synthetic which do not have the same properties or benefits. You want to be sure you look for the 100% organic latex. There are other certifications as well including Oeko-Tex 100 & The GOLS certification which touch on other environmental impact issues. To learn more read this.

What are the Health and Environmental benefits of Latex foam?

Natural latex is a 100% natural product from renewable sources. It’s resistant to mold, dust and allergens. It’s also naturally fire-resistant and doesn't need chemical flame retardants. Natural latex is biodegradable and recyclable, so it has a minimal carbon footprint. Of course if you have a latex allergy you would want to pass on this product.

How does the price compare and where can you find it?

Latex foam can cost a minimum of three times the price of your typical high quality polyurethane foam. It is very durable and can last decades depending on use. One reason for the cost is that the trees are only grown in India and Southeast Asia and the material needs to be shipped.

Fun fact: Latex foam is made for the mattress industry. Vendors will purchase the mattresses and cut them down to size to sell to the upholstery industry. This, as well as lower demand at this point, is why it’s harder to find a source that carries it. I used foamorder.com for my supplies. You can buy large sheets or have them cut to size. They will wrap and cover for you as well.

Is there any special handling or prep for this product? 

Latex foam is manufactured in a way that creates holes in the foam. To minimize the effect the holes have on the finished product, it is typically wrapped with some kind of batting. Options for wrapping are: wool batting, cotton batting or Dacron. 

Wool batting- For those with chemical sensitivities or a desire to use all natural products, wool is a great choice. Wool is a sustainable and renewable natural fiber. It’s warm and breathable.

Organic cotton batting- is known for being incredibly soft, breathable, and durable. Certified organic cotton batting is natural, meaning it doesn’t contain toxins or chemicals such as boric acid. 

Dacron- A polyester fiber, hypoallergenic, non-absorbent, and mildew-resistant. It’s the least expensive option.

Consumers interested in latex foams benefits usually choose wool or cotton. If wool batting is used you will also need to create a cover to prevent the wool from shifting or pilling through your top fabric. Typically organic cotton ticking is used. The ticking cover can be of simple construction using staples, glue, or hand sewing to close the cover. You’ll want it to fit a little loose so that it fills out the corners of the final cover.

Wrapping foam is not a foreign concept. Generally regular foam is wrapped with dacron to promote longevity and help fill out the cover. The additional step of making a ticking cover needed for wool batting will obviously take a little more time and labor. Other than that latex foam is handled very similarly to regular foam. It can be cut down with a typical foam saw. You don't need to worry about the holes, if you cut through them it's okay, the batting will hide it. Lastly you can use your same calculations for sizing of foam vs cover size.

What firmness/Density should you choose?

The two suppliers that I contacted did not offer pound (lb) and IFD ratings. Or at least I couldn’t find that information. They did however give their recommendations based on thickness and use. There are several firmnesses available. I would encourage you to order samples if possible.

Note: latex foam weighs considerably more than a comparable firmnesses of polyurethane foam. My clients cushions were long and I could feel a significant difference in the weight.

My clients banquette seating cushions completed with latex foam and a washable eco-friendly fabric. She requested a fitted sheet style cover so that it would be easily removed. A decision that worked out beautifully once we discovered how heavy the foam was. A zippered cover would have made it much harder to remove them. That style was another first for me.

I hope that gives you just a taste of what the benefits of latex foam are and how to work with it. It's something to consider if you have either chemical sensitivities or a desire to make more environmentally conscience choices. As with anything related to the environment there’s so much to consider. It's not about making the perfect choice, only making the best choice you can.

If you'd like to dig deeper into the subject of natural materials, as I've only touched on the tip of the iceberg and am not an expert by any means, I encourage you to check out my friend Carla's website, naturalupholstery.com It was the first place I looked for answers to my questions, she's the expert on the subject and her website is packed with great information and tutorials. 

-Michelle