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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.

Custom Sewing

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Our professional seamstresses can handle any custom sewing job

We sew fabric and vinyl covers to meet all of your needs. Here, in our sewing section, you can order specialty fabric covers for foamorder.com® items, or you may order just the fabric cover alone. We sew a zipper into each of the patterns for easy cover removal.

If you don’t have a standard shape, select “Pattern Shapes” from the shapes below and follow instructions for creating and mailing us your own custom shape pattern. We sew our custom covers both inside and out.

This prevents the fabric from unraveling on the inside when cleaned. All of our covers should be dry-cleaned only. There are no returns or cancellations on any custom sewn products.

Custom Sewing

Wide variety of fabrics and material types

We carry several lines of fabric: Sunbrella brand, our own discount fabric, the Robert Allen Fabric line, certified organic cotton muslin, and hemp fabric. In addition we carry a line of Nautilus Marine Vinyl. You can also send us your own fabric. We will give you instructions at the conclusion of your order on how to mail your fabric to us.

Custom Sewing

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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, Midnight Navy, and Charcoal Gray discount fabrics are all very dark shades of fabric. 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.