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Custom Sewing

Custom Sewing
Notice

This page is for orders of custom sewn covers only. To order replacement or new cushions with custom sewn covers, please start at our custom cushions page.

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Step 1: Choose a fabric option

Do you need a cover and the foam filler? You can order your complete piece (foam and fabric cover) by visiting our custom cushions section. Choose a “custom cut” shape, enter your dimensions, and then select your fabric and foam from the available options.

Pick a shape below and fill in the dimensions, and we will provide you with an estimate of how many yards of fabric you will need, rounded up to the next half yard. This estimate does not take into account which direction you may want stripes to go (if there is a pattern). If your fabric has a directional pattern, you may need to supply more fabric. Contact us for help estimating.

After submitting your order you will be able to print a pre-addressed form with your order number on it. Tape this to the outside of your envelope and mail your fabric to our shop. Note that your credit card will not be charged for this item until we receive your fabric.


Sunbrella Sewing

Click here to choose a fabric

Enter number and name. Example: “5403-0000 Canvas Jockey Red.”

Our most complete line is by Sunbrella. Sunbrella is the leading brand in exterior/interior fabrics. Sunbrella fabric is UV treated not to fade for 3 years. You may choose from a variety of colors and prints. If you select a striped Sunbrella fabric, we recommend that the cording be a solid color that will match one of the stripe colors.


See color swatches

As a fabric, hemp provides all the warmth and softness of a natural textile but with a superior durability seldom found in other materials. Hemp is extremely versatile and can be used for countless products such as apparel, accessories, shoes, furniture, and home furnishings.

Apparel made from hemp incorporates all the beneficial qualities and will likely last longer and withstand harsh conditions. We hope that our collection will inspire you to create things that not only look beautiful and feel wonderful, but are also gentle to the earth. NOTE: No two lots of natural hemp fabric will be the exact same color.


These fabrics are typically an 8 oz. durable fabric, usually a poly-cotton twill.

Discount fabric cover color chart

(Colors may vary due to monitor differences.)

Please note that the Black and Midnight Navy discount fabrics are very dark shades of fabric. The Gray fabric is a lighter shade as shown. Orders are not returnable based on color selection.


Muslin is a looser weave fabric used primarily as an inner lining fabric with an exterior finished fabric used on top of it. Muslin may be used as an exterior fabric for some applications, such as a case for a mattress pad or a foam block. It is not heavy enough to be the only fabric for natural latex—it will allow too much airflow and subsequent crystallization of the natural rubber as the latex dries out. For covering latex we suggest this fabric in combination with our organic cotton mattress ticking.


Robert Allen

Click here to browse Robert Allen fabrics. Click on any fabric swatch for more information. Enter the full pattern or color name listed with the pattern (for example: “Vertical Stems | Driftwood”) in the box above.

You can usually find Robert Allen Fabrics at your local upholsterer. You can browse through this line, order the fabric directly from us and save money on your sewing fees.

Please note: because Robert Allen fabrics differ so widely in price, our quote will not include the cost of the material. Our price quote is for the cost of the sewing labor only. We will contact you to confirm the total price, including fabric, before charging your credit card for this sewing project. If you also order foam, the foam portion of your order will be processed without delay.


See color chart. Copy the item name and number (example: “Cloud White #734311”), then paste it in the box above.

Our marine vinyl is known for its outstanding resistance to stain, mildew, abrasion, bacteria, common scuffing, fading, and burnishing. Both our Interior (Grades A & B) and Exterior expanded vinyls are excellent choices for marine upholstery, as well as for projects within the kitchen, bath, and home. The sturdy, expanded construction utilizes a heavy-duty, 100% polyester filament backing that has superior strength and great stretch and set qualities. They are all available in 54-inch widths. Day-to-day clean-up is simple with a solution of mild soap and warm water. Non-abrasive household cleaners may be needed for more difficult stains, and used according to manufacturers’ instructions.

Although all grades (for both Interior and Exterior) provide excellent protection and quality as described above, Nautilus Grades A & B Interior go a step further with additional flexibility and comfort while providing better resistance to UV fading and water damage. They are also coated with PreFixx® protective finish, which provides stronger resistance against staining and allows exceptional ease of cleaning. We recommend choosing Nautilus Grades A & B Interior on softer foam cushions, down cushions, or for better protection against sunlight and general wear. All three types have a five-year manufacturer’s warranty, and meet California Flame Retardant rating (#117, Section E). Color availabilities vary for both Interior and Exterior choices.

Step 2: Choose a cover shape

After selecting your fabric type above, please click on the shape below that closest resembles what you would like to order. After, you will be asked to enter in the dimensions, and after that you will be given a price quote based on your selections.

Frequently Asked Custom Sewing Questions

Do you need a cover and the foam filler?

You can order your complete piece (foam and fabric cover) by visiting our custom cushions section. Choose a “custom cut” shape, enter your dimensions, and then select your fabric and foam from the available options.

Why and How Should I order Welt Cording with my Cushion?

Welt cording makes any fabric covered pillow or cushion look complete and professional. We painstakingly match the pattern in the front with the pattern on top despite the seams cut and sewn for cording. This is very difficult and requires skilled sewing. You may mix and match colors of fabric and cording. If you select a striped Sunbrella® fabric cover, we recommend that you select cording in a solid color that will match one of the stripe colors. (Note that cording is not necessary for mattress covers.)

What is Top Stitching?

Create a contemporary or modern looking cushion by top-stitching instead of adding welt cord. If using top stitching, we recommend that you order the foam one-half inch thicker than the casing to stretch out the fabric if you don’t have a Dacron wrap or down envelope added. If you want you can specify a different color thread to be used for the top stitch by adding comments to the cover item once it is in your shopping cart.

Can you add chair ties or velcro to my custom cushion?

We can add chair ties (or cushion ties) to any cushion shape. The ties will be made from the same material used to make your cover. Chair and cushion ties are purchased by the set—a set is made up of the two individual strips that tie together to form one “knot,” holding your cushion in place against the furniture. For vinyl covers, a set of velcro ties is made up of two individual half-inch wide strips that overlap and connect firmly with velcro backing in order to form one “knot.” We highly recommend using no less than TWO SETS of ties to secure your cushion to your furniture. You can specify where the chair ties should be placed on your cover after clicking the “Add to Cart” button. We also offer velcro strips on your sewn covers for an extra charge. Place comments in your shopping cart, or contact our customer service team for help.

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Four Seasons Hotels and Resorts, San Francisco Giants, Mezeh
Willow Creek Golf Club, Sorinex, Wanderful Wheels

What Our Customers Are Saying About FoamOrder

5/5 stars
Amazing product and experience!
“I ended up calling it to get the help I needed and was wildly impressed with the knowledge and help from the rep I spoke with. I have since received my custom cushion covers and am loving the end product as well! Ordered more covers and will always refer to this company for my cover and cushion needs. At the end of the day you might as well go 'custom' from Foam Order rather than something off the shelf.”
P.P.
Charleston, SC
November 2022
5/5 stars
Most helpful and knowledgeable Customer service folks in the industry
“We did research by reaching out to a number of companies that do custom Cushions. We wanted to make sure the foam we picked was the right kind for Outdoor use. The ones that will drain water and will also be firm. We got the guidance we were looking for and every one from Order placement to finally picking up the cushions from the Richmond warehouse were extremely helpful. The order was completed in the timeframe they expected to have it all ready and we are extremely please with our new cushions. Since then we have ordered three more foam (only) for existing covers.”
Marin Customer
Corte Madera, CA
October 2022
5/5 stars
Superb product and company!
“I cannot praise this company and their product more. We now have custom ordered two full sets of cushions and with their customer service help, have been thrilled with the end product! Cannot recommend them more highly!”
Cathy T
Arlington, VA
October 2022

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