Measure your cushion cover between the seams — not the old foam — with the foam still inside the case. Old foam has compressed over time, so it is no longer an accurate guide to the size your replacement should be.
For step-by-step diagrams, read our guide on how to measure foam cushions.
The best foam for indoor couch cushions used most days is high-resilience polyurethane foam. For most people that means our medium-firm V44 Everflex foam (2.8 lb/ft³ density, ILD 44) in cushions between 4 and 6 inches thick. If your cushion is thinner than 4 inches, choose the firmer V54; if it is thicker than 6 inches, choose the softer V34.
We offer two main foam families for indoor couch and sofa cushions: traditional polyurethane (free of harmful chemicals) and organic latex. For occasional-use seating in guest rooms or seldom-used areas, our lower-cost Econoflex foam is a sensible value option. For organic latex, we recommend medium N31 or medium-firm N36 for standard-thickness cushions. You can also add memory foam as a top layer above a firmer polyurethane base for a body-contouring feel.
Not sure which to pick? Compare options on our organic latex foam page or contact our customer service team for help with ordering.
Yes — we recommend dacron batting on every couch and sofa cushion, usually as a book wrap. Batting gives an upholstered cushion that full, comfortable, rounded look; without it, new custom cushions will show wrinkles in the fabric.
If you need extra padding around your cushion, consider a double-dacron book wrap, or wrap all sides. For our high-end organic latex cushions, we recommend organic cotton or organic wool batting with an organic cotton wrap, which keeps the build all-natural while providing premium padding. We guarantee you’ll feel the difference.
If you really don’t want any batting, order the foam slightly thicker (1/4" to 1/2") than the case to make sure it fills the cover as much as possible.
Most couch and sofa cushions should be between 4 and 6 inches thick. When ordering replacement cushions, keep the thickness the same as the original so you can reuse the slipcovers that came with the couch.
If you are ordering brand-new cushions, any thickness that works within the design of the couch is fine — but more than 6 inches is usually unnecessary, and thinner than 4 inches may lead to heavier users “bottoming out” and hitting the support materials below the cushions. The top of a seat cushion should generally sit between 18" and 20" from the floor; any taller and some people won’t be able to rest their feet comfortably on the floor.
“This is just night and day from the old couch that we had.”
“I was just very motivated to get new inserts & bring the couch back to life.”
“Brand new cushions in an old couch — this is exactly what we wanted.”
“It looks like a brand new, so I’m really happy with the purchase.”
“It just feels like having new furniture again.”
A FoamOrder replacement couch or sofa cushion isn't pulled off a shelf — it's built one decision at a time. Open any step below to see exactly what you control, from the core out to the stitching.
Start with the shape selector above, then give us your exact dimensions. Nothing is rounded to a stock size — every cushion is cut to your numbers.
You'll also set the unit of measurement, whether it's a seat or back cushion, and the quantity. Not sure how to measure? See our How to Measure for Foam Cushions guide.
Pick a foam family for how your couch, sofa, or bench cushion will be used, then a specific foam. Density (lb/ft³) drives durability; firmness is rated by ILD (Indentation Load Deflection) — the higher the number, the firmer the seat.
Open-cell polyurethane, free of fire-retardant chemicals, in three quality tiers. EverFlex is our premium high-resilience line; DuraFlex is the mid-tier; EconoFlex is the value option for occasional-use seating.
| Foam | Tier | Feel | Density (lb/ft³) | ILD |
|---|---|---|---|---|
| V24 | EverFlex | Soft | 2.6 | 24 |
| V34 | EverFlex | Medium | 2.6 | 34 |
| V44 | EverFlex | Firm | 2.8 | 44 |
| V54 | EverFlex | Extra-firm | 2.9 | 54 |
| D30 | DuraFlex | Soft | 2.2 | 30 |
| D40 | DuraFlex | Medium | 2.2 | 40 |
| D50 | DuraFlex | Firm | 2.2 | 50 |
| C25 | EconoFlex | Soft | 1.8 | 25 |
| C33 | EconoFlex | Medium | 1.8 | 33 |
| C55 | EconoFlex | Extra-firm | 1.8 | 55 |
Higher-density foam lasts longer. A medium-firm V44 suits most 4–6" couch and sofa cushions — choose the firmer V54 for thinner cushions and the softer V34 for thicker ones.
GOLS-certified organic latex made from rubber-tree sap — naturally breathable, antimicrobial, and biodegradable, at roughly 5.9 lb/ft³ density throughout.
| Foam | Feel | ILD |
|---|---|---|
| N25 | Softest | 25 |
| N28 | Soft | 28 |
| N31 | Medium | 31 |
| N36 | Medium-firm | 36 |
| N45 | Firmest | 45 |
For standard-thickness latex couch cushions, medium N31 or medium-firm N36 is the most popular choice.
Slow-contouring, body-hugging foam (5.3 lb/ft³, ILD 13). Best used as a top layer over a firmer base to avoid excessive sink and improve longevity.
Open-cell foam that promotes airflow and drains quickly — built for covered or exposed seating in moisture-prone spots.
| Foam | Feel | Density (lb/ft³) | ILD |
|---|---|---|---|
| Outdoor 25 | Soft | 1.8 | 25 |
| Outdoor 33 | Medium | 1.8 | 33 |
| Outdoor 45 | Firm | 1.8 | 45 |
Lightweight, budget foam (1.2 lb/ft³) for shipping and light-use padding. Not built for repeated compression — choose a seating foam above for cushions in regular use.
A wrap goes around the foam to round its edges and fill out the cover for a finished, upholstered look. Dacron is standard and strongly recommended on every cushion — without a wrap, fabric tends to look baggy and wrinkled.
Polyester batting wrapped around the foam. Choose where it wraps (book vs. all sides) and how much (single vs. double thickness):
A self-fluffing down envelope cradles you in pillowy comfort; the foam inside re-lofts the down every time you stand up.
A 1"-thick (25 mm) layer of 100% cotton batting, then a custom-sized, zippered 100% cotton case that slides easily into your fabric cover.
Keeps the build all-natural while solving latex's two cosmetic quirks: it hides the pin-holes that show through thin fabric and prevents a baggy, sloppy look.
Top your cushion with a fabric cover, or skip it. Our library spans 5,000+ fabrics from leading mills:
Narrow them down by:
| Filter | Choices |
|---|---|
| Application | Indoor, Nautical, Outdoor |
| Fiber | Natural fibers, synthetic fibers, natural/synthetic blends, vinyl & coated textiles |
| Pattern | Textured solids, geometric, stripes & lines, floral & botanical, plaid & checks, abstract, ethnic & global, classical, animal & skin, nautical & marine, novelty |
| Color | Primary & secondary across the full spectrum (aqua, beige, blue, brown, green, grey, ivory, orange, pink, purple, red, white, yellow, and more) |
| Price | Three tiers, from value ($) to premium ($$$) |
Two flexible paths if none of those fit:
Want to see what's available first? Browse upholstery fabric by the yard.
This is where a custom cushion pulls ahead of a factory one — dial in the construction details:
Overlocking sews and finishes the inside fabric edges so they can't fray or unravel. We consider it essential on cushions — it's what keeps a cover intact through years of zipping and washing.
A tailored, polished look with a reinforced edge. Match it to your cover fabric for a seamless finish, or pick a contrasting fabric to make the edge pop.
A refined, durable finish stitched along the edge that enhances both style and longevity — a clean alternative to cording.
Keep the cushion anchored in place with chair ties (two strands per set, sewn from your cover fabric and knotted) or Velcro straps. Order up to eight sets, and specify placement, spacing, and tie length — 10" (25 cm) is standard.
Choose where the zipper goes — it's flapped and hidden, so you decide where it sits:
| Option | How it works |
|---|---|
| Across a side | Runs along the width, depth, or back/bottom — centered on the longest edge of that side. |
| Around the middle | Wraps three sides at mid-thickness; best for cube-shaped cushions over 10" thick and custom foam mattresses. |
| Custom location | Describe exactly where you want it, or send a marked diagram. |
Every one of these is yours to set — and every replacement cushion is still cut to order in the U.S.
Buy custom-cut foam inserts that replace flat, worn-out sofa and couch cushions, made to fit your furniture exactly.
Couch cushions eventually wear out after years of dutiful use, but a made-to-order replacement will make them comfy and plush again. Every cushion is cut to your own measurements or pattern, so it fits your couch, sectional, chair, or ottoman exactly the way the original did. Rather than pulling a stock size off a shelf, FoamOrder builds each one to your specifications—seat or back, firmness, thickness, and finish.
Don’t see the shape you need? No problem. Just choose “Pattern Shape” to make your own pattern and send it to us to cut to your exact pattern specifications.
How to Order Custom and Replacement Cushions
Measure Your Cushions
Precisely measure the shape and dimensions of your cushion for the best possible fit. (see how)
Select Your Foam
Select from over 30 foam types based on your cushion’s location, use, and feel.
Select a Fabric
Choose the texture and style of the fabric for your cushion covers, or skip this step for foam only.
We’ll Do the Rest
FoamOrder will size and cut your custom cushions and ship them right to your door!
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