How thick foam can be depends on type and manufacturing, but foam can be made in wide range of thicknesses from very thin sheets of 1 millimeter to large blocks several feet thick. For furniture and mattress foam, typical thicknesses are 1 inch to 6 inches per layer, with mattresses stacking layers to total 8 to 14 inches thick, and foam blocks for upholstery can be cut up to 6 to 8 inches thick. For insulation, rigid foam boards are commonly 0.5 inch to 4 inches thick, but can be layered to achieve greater thickness, and spray foam can be applied in layers to reach several inches thick, with closed cell spray foam typically limited to 2 inches per pass but can build to 4 inches or more. Industrial foam blocks can be manufactured up to 3 to 4 feet thick for large applications like floatation or packaging. Craft foam sheets are thin, about 2mm to 10mm. So foam thickness is highly variable, from paper thin to several feet, with practical limits set by manufacturing equipment, curing, and application needs, and custom thicknesses can be made for special purposes.
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