Custom Outdoor Cushions

Over 1,000 5-star Reviews

Custom Outdoor Cushions

Made-to-order cushions for patio chairs, sofas, benches, and chaise lounges, cut to your exact dimensions in any shape. Choose dry-fast outdoor foam and Sunbrella or other weather-resistant fabrics, or order complete cushions, foam inserts only, or covers only.

Custom outdoor cushions from FoamOrder are cut and sewn to the measurements you enter, not pulled from a stock size. Pick a shape below, from simple rectangles to curved L and T cushions, wedges, bolsters, and traced patterns, then enter the length, width, and thickness of your seat. Choose a firmness of dry-fast reticulated outdoor foam that drains and dries instead of holding water, and a cover in Sunbrella or another fade-resistant, mildew-resistant fabric in the color and pattern you want.

Custom Outdoor Cushion Reviews from Real Customers

Jennifer S
Lake Frederick, VA Custom foam inserts for wicker chair cushions

“Like-new chairs for a fraction of the cost of buying new.”

Kelly P
Myrtle Beach, SC Custom 4-inch outdoor foam for cabana cushions

“I don’t have any sink. My back is supported. Firm in a good way.”

Deanna S
Delray Beach, FL Custom outdoor daybed mattress

“It is not sagging. It’s thick. It’s supportive. And it was easy to order.”

Andy L
Houston, TX Custom outdoor cushion covers for patio chairs

“These covers fit on the cushions like a glove.”

Build Your Outdoor Custom Cushion

An outdoor cushion from FoamOrder is not pulled off a shelf. It is built one decision at a time, for sun, rain, and everyday use. Open any step below to see exactly what you control, from the quick-dry core out to the stitching.

Shape & Size Standard shapes · rounds & bolsters · window seats · custom pattern

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, whether it is for a patio chair, bench, chaise, daybed, or wicker frame.

Standard shapes — rectangle & square, L-cushion and T-cushion (straight or curved), trapezoids, parallelograms, and polygons.
Rounds & bolsters — cylinders, bar stools, semicircles, wedges, and bolsters (including V-berth and clipped).
Window seats & multi-piece — equilateral and clipped window seats, plus two- and four-piece chair and lounge sets.
Custom pattern — don't see your shape? Choose "Pattern Shape," trace your cushion, and send it to us to cut to your exact template.

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.

Outdoor Foam Quick-dry open-cell foam · soft to firm (ILD 25 to 45)

Open-cell quick-drying outdoor cushion foam

Outdoor cushions need foam that breathes and drains. Our outdoor foam is open-cell and quick-drying. It promotes airflow and sheds water fast, and it is built for covered or exposed seating in moisture-prone spots. Firmness is rated by ILD (Indentation Load Deflection): the higher the number, the firmer the seat.

Foam	Feel	Density	ILD
Outdoor 25	Soft	1.8 lb	25
Outdoor 33	Medium	1.8 lb	33
Outdoor 45	Firm	1.8 lb	45

Outdoor 33 (medium) handles most patio seat cushions. Go firmer with Outdoor 45 for thinner cushions, deep-seating bases, or high-traffic commercial seating. Choose the softer Outdoor 25 for backs and plush lounge cushions.

Dacron Wrap Polyester wrap · book or all sides · single or double

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. It pairs naturally with quick-dry foam and a breathable outdoor cover.

Dacron Wrap: four configurations

Polyester batting wrapped around the foam. Choose where it wraps (book vs. all sides) and how much (single vs. double thickness):

Single Dacron book wrap around cushion foam — Book Wrap

Dacron wrap on all sides of cushion foam — Wrap All Sides

Double-thickness Dacron book wrap — Double Book Wrap

Double Dacron wrap on all sides — Double All Sides

Book Wrap — single Dacron wrap across the top and bottom.
Wrap All Sides — single Dacron wrap fully enclosing the foam.
Double Dacron Book Wrap — double-thickness wrap across the top and bottom for a plusher crown.
Double Dacron All Sides — double-thickness wrap fully enclosing the foam.

Covers & Fabric 5,000+ fabrics · Sunbrella & marine-grade · full specs · or supply your own

For an outdoor cushion, the fabric is the decision that matters most. It is what stands up to sun, rain, and mildew, and what you will look at every day. Top your cushion with a weather-ready cover, or skip it. Our library spans 5,000+ fabrics from leading mills, led by solution-dyed and marine-grade lines built to take the elements:

Brands — Sunbrella, Robert Allen, Premier Prints, Trivantage, and our own FoamOrder line.

For fully exposed seating: Sunbrella (solution-dyed acrylic) and vinyl-coated marine fabrics are the two lines in our library rated for full sun and rain. Sunbrella is water-repellent and fade-resistant rather than waterproof, and vinyl sheds water outright. Every other fabric holds up best in covered, shaded, or screened-in spots.

Add-on: CompleteSeal Stain & UV Guard

CompleteSeal fabric protection treatment for stain and UV guard

For fabrics that need more outdoor protection, we can pre-treat your cover with CompleteSeal fabric protection to guard against stains and UV rays, keeping your cover looking fresh and colorful for years. It offers a permanent reduction in staining and soiling, smoke density (23%) and flame spread (14%), sun bleaching and mildew, static electricity, and cleaning costs. Backed by a 3-year warranty. CompleteSeal isn't necessary for Sunbrella fabrics or vinyl covers, which already resist the elements.

Compare on performance, not just looks

Because the cover does the heavy lifting outdoors, every fabric in our library carries a full technical spec, so you can choose on how it performs, not just how it looks:

Durability — abrasion resistance in double-rubs (Sunbrella rates around 45,000), plus construction and weight (oz per linear yard).
Weather performance — water-repellent and water/stain-resistant finishes, weather protection rating, and mildew resistance.
Care — the fabric's cleaning code (W, WS, BC) tells you exactly how to clean it.
Make-up — fiber and fabric content (solution-dyed acrylic, vinyl-coated polyester, blends), finish, collection, and width.
Fit & planning — pattern repeat (horizontal & vertical), roll size, and put-up for larger and multi-piece projects.
Peace of mind — recyclability, CA Prop 65 status, and listed use cases (cushions, marine & outdoor upholstery, pillows, umbrellas).

Narrow them down by:

Filter	Choices
Application	Outdoor, Nautical
Fiber	Solution-dyed acrylic, synthetic fibers, vinyl & coated textiles
Pattern	Textured solids, geometric, stripes & lines, floral & botanical, plaid & checks, abstract, nautical & marine, novelty
Color	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:

Foam only — reuse your existing covers; no fabric needed.
Supply your own (COM) — send us a fabric you love and we'll sew the cover from it.

Finishing Touches Overlock · welt cording · ties · zipper placement

This is where a custom cushion pulls ahead of a factory one. Dial in the construction details:

Edge finish: Overlock

Overlocked inside fabric edges preventing unraveling

Overlocking sews and finishes the inside fabric edges so they can't fray or unravel. We consider it essential on cushions that live outdoors. It is what keeps a cover intact through years of zipping, washing, and weather.

Edge style: Welt Cording or Top Stitching

Welt cording piping on a cushion edge — Welt Cording

Top stitching on a cushion edge — Top Stitching

Welt cording — 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.
Top stitching — a refined, durable finish stitched along the edge that enhances both style and longevity; a clean alternative to cording.

Attachment: Chair Ties or Velcro Straps

Keep cushions anchored against wind 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.

Closure: Zipper Placement

Diagram of zipper placement across the width of a cushion cover

Choose where the zipper goes. It is 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 cushion is still cut to order in the U.S.

How to Order Custom 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!

Select your Outdoor Cushion Shape

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.

﻿Need help with design or measuring? Get Help from our Customer Service experts!﻿

Frequently Asked Custom Outdoor Cushion Questions

How do I order custom outdoor cushions?

Start with the cushion shape above, then enter your exact dimensions in inches or centimeters. Next, choose an outdoor foam and firmness, pick a fabric or skip it if you only need foam, and add finishing options like Dacron wrap, welt cording, zipper placement, and chair ties. We cut and sew each cushion to your measurements, so there is no standard size to fit into. If you are ordering replacement cushions for furniture you already own, measure the cover seam to seam rather than the worn foam. Our how to measure guide walks through it, and our customer service team can review your numbers before we cut.

What shapes and sizes of outdoor cushions can you make?

More than 30 shapes, in any dimensions. Rectangles and squares cover most patio chair, sofa, and bench seats. L-cushions and T-cushions, straight or curved, wrap around chair arms. Trapezoids, parallelograms, and five- or six-sided polygons fit angled wicker and cast-aluminum frames. Rounds, semicircles, wedges, bolsters, and window seat shapes are all available, along with two- and four-piece sets for chaise lounges and adjustable loungers. If your furniture does not match any of these, choose Pattern Shape, trace the seat or the old cushion, and send us the template. We cut to it exactly.

Which outdoor foam should I choose, and how firm should it be?

All of our outdoor cushions use dry-fast reticulated foam, an open-cell foam that lets rain drain straight through and air-dry instead of holding water. It is a durable 1.8 lb density foam, which holds its shape and comfort far longer than the 1.2 lb foam used in many store-bought patio cushions. It comes in three firmness levels. Medium (Outdoor 33) is the most popular choice for 3 to 4 inch patio seat cushions. Firm (Outdoor 45) suits thinner cushions, deep seating sofas, and heavy daily use. Soft (Outdoor 25) works well for back cushions and thick, plush chaise lounge cushions. The custom cut outdoor foam page has full specifications.

How thick should custom outdoor cushions be?

Most outdoor seat cushions are 4 to 5 inches thick. Dining chair pads are usually 2 to 3 inches, deep seating and sofa cushions run 5 to 6 inches, and chaise lounge cushions are typically 3 to 4 inches. If you are filling covers you already own, match the original thickness so the foam fills the cover without bulging. If you are ordering complete cushions, you can change the thickness as long as the cushion still fits the furniture. For seating, aim for the top of the seat cushion to sit 18 to 20 inches from the floor.

Which fabrics do you offer for outdoor cushions?

Our library includes more than 1,000 fabrics. For outdoor use, most customers choose Sunbrella, a solution-dyed acrylic performance fabric available in hundreds of colors and patterns that resists fading, mildew, and stains. We also carry performance vinyl for high-traffic and marine seating, organic hemp canvas, and designer fabrics from Robert Allen and Premier Prints. If you are checking whether a fabric is UV-resistant, look for solution-dyed acrylic, olefin, or a performance rating on the product page. You can also send us your own fabric and we will sew the covers from it. Browse the full selection on our upholstery fabric by the yard page.

Can I order fabric samples before I buy?

Yes. Fabric swatches cost $1.99 to $5.99 each depending on the brand, so you can compare colors, textures, and weights in your own light before placing a cushion order. Samples are available for Sunbrella and the rest of our outdoor fabrics on the upholstery fabric by the yard page.

Are custom outdoor cushions waterproof?

Water-resistant is the accurate term for most outdoor cushions. Sunbrella and similar performance fabrics repel water and dry quickly, but a heavy rain will eventually soak through the seams and zipper. That is why the foam matters more than the cover. Our dry-fast reticulated foam drains from every side and air-dries in hours, so a soaked cushion recovers instead of staying waterlogged and growing mildew. After a storm, stand cushions on edge for a few minutes to speed drainage. For seating that stays wet, such as boats and pool decks, performance vinyl covers add another layer of protection.

What's the difference between indoor and outdoor cushions?

The difference is how the foam handles water. Indoor cushions use high-density polyurethane foam, which soaks up water like a sponge and takes days to dry, leading to mildew if it gets wet. Outdoor cushions use open-cell reticulated foam that lets water pass straight through and air circulate, so the cushion dries quickly and stays fresh. Outdoor covers are also sewn from fade-resistant, mildew-resistant fabric. If your furniture lives on a screened porch or under a covered patio where it rarely gets wet, either foam works, and indoor foam will feel plusher.

Can I leave outdoor cushions outside in the rain or winter?

Outdoor cushions are built for weather, but constant exposure shortens their life. Rain is not a problem for dry-fast foam as long as the cushion can drain. Freezing temperatures and months of direct sun are harder on the fabric and stitching than on the foam, so covers usually show wear before the foam does. Covering or storing cushions during the off season is the simplest way to extend their life. If storage is not an option, use furniture covers, keep cushions off the ground, and make sure water can drain out of the zipper end.

How do I clean outdoor cushions?

Every cover we sew has a hidden zipper, so you can remove it for cleaning. Sunbrella and similar performance fabrics can be cleaned with mild soap, water, and a garden hose, or machine washed on cold and air-dried. For mildew or tough stains, Sunbrella allows a diluted bleach solution, following the cleaning guide on their site. The foam itself can be hosed off and stood on edge to drain. Avoid pressure washers and high-heat dryers, which break down fibers and stitching.

Can I buy just the foam inserts, or just the covers?

Either one. If your existing covers are still in good shape, order foam inserts only from the shape selector above and slide them into the covers you have. If the foam is fine but the fabric has faded or torn, order custom cushion covers without foam. We sew replacement covers for seat cushions, back cushions, and decorative pillows to your dimensions in the fabric you choose, with the same zipper, welt cording, and tie options as a complete cushion. Most cushion companies only sell the complete cushion, so this is a good way to fix the part that failed without paying for the part that did not.

Can I buy outdoor fabric by the yard and make my own cushions?

Yes. We sell Sunbrella, performance vinyl, hemp canvas, and other outdoor fabrics by the yard, and you can pair them with custom cut outdoor foam to sew your own cushions. Fabric ships from our workshop within about a week. Start with the upholstery fabric by the yard page, and if you are new to sewing cushions, our guide on how to make your own outdoor cushions covers the materials and steps.

Do you make custom cushions for outdoor sofas, chaise lounges, benches, and wicker furniture?

Yes, along with most other outdoor seating. We make outdoor sofa, loveseat, sectional, and deep seating cushions, chaise lounge cushions, outdoor bench cushions, outdoor chair and seat cushions, back cushions, cushions for wicker furniture, outdoor daybed mattresses, and ottoman cushions, plus boat cushions and RV cushions. Porch swings, gliders, and window seats use the bench and rectangle shapes. If you want everything in Sunbrella, see our Sunbrella cushions page.

How long does it take to receive my cushions, and where are they made?

Foam inserts only usually ship within 3 to 14 days. Complete cushions with sewn covers usually ship within 4 to 6 weeks, since each cover is cut and sewn to order. Everything is cut and sewn in the USA at our workshop in Northern California, and shipping is from there, so there is no overseas transit time. For bulk orders or a faster turnaround, contact our customer service team before ordering and we will tell you what is possible.

How do FoamOrder's custom outdoor cushions hold up over time?

Our outdoor foam cushions carry a 15-year limited warranty, prorated after 7.5 years, and sewn covers carry a 1-year limited warranty. Details are on our warranty page. Beyond the warranty, nearly 200 customers have reviewed their outdoor cushions with us at an average of 4.6 out of 5, and the most common comments are about fit, support, and cushions that no longer sag. You can read every one of them on our outdoor cushion reviews page.

Outdoor Foam, Covers, and Fabric Sold Separately

Replacement deep seating foam and custom outdoor cushions tailored for a wicker sectional sofa set.

﻿Replacement Cushion Covers﻿

Weatherproof replacement foam and custom outdoor cushions designed for a circular exterior lounge chair by the pool.

﻿Custom Cut Outdoor Cushion Foam﻿

foldable foam pad that can be used as an indoor or outdoor mattress or stunt pad

﻿Outdoor Fabric by the Yard & Swatches﻿

Custom outdoor cushions designed as high-quality replacements for popular patio furniture brands and luxury sectional sets.

﻿Foam Samples﻿

﻿Outdoor Foam Sheets﻿

﻿Closed Cell Foam﻿

﻿Dacron Batting﻿

Looking for Something Else?

Indoor Cushions

Cushion fabricator making an outdoor cushion

Cushion Covers & Fabrics

multiple upholstery foam sheets folding over themselves

﻿Upholstery Foam﻿

High-durability custom outdoor cushions tailored for country club decks, restaurant patios, and hospitality settings.

﻿Commercial Cushions﻿

﻿Mattresses﻿

Over 100,000 Satisfied Residential and Commercial Customers, including:

What Our Customers Are Saying About FoamOrder
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Select Custom Outdoor Cushion Type

Custom Outdoor Cushion Reviews from Real Customers

Build Your Outdoor Custom Cushion

Select your Outdoor Cushion Shape

Frequently Asked Custom Outdoor Cushion Questions

How do I order custom outdoor cushions?

What shapes and sizes of outdoor cushions can you make?

Which outdoor foam should I choose, and how firm should it be?

How thick should custom outdoor cushions be?

Which fabrics do you offer for outdoor cushions?

Can I order fabric samples before I buy?

Are custom outdoor cushions waterproof?

What's the difference between indoor and outdoor cushions?

Can I leave outdoor cushions outside in the rain or winter?

How do I clean outdoor cushions?

Can I buy just the foam inserts, or just the covers?

Can I buy outdoor fabric by the yard and make my own cushions?

Do you make custom cushions for outdoor sofas, chaise lounges, benches, and wicker furniture?

How long does it take to receive my cushions, and where are they made?

How do FoamOrder's custom outdoor cushions hold up over time?

Outdoor Foam, Covers, and Fabric Sold Separately

Looking for Something Else?

Custom Outdoor Cushion Reviews from Real Customers

Build Your Outdoor Custom Cushion

Frequently Asked Custom Outdoor Cushion Questions

How do I order custom outdoor cushions?

What shapes and sizes of outdoor cushions can you make?

Which outdoor foam should I choose, and how firm should it be?

How thick should custom outdoor cushions be?

Which fabrics do you offer for outdoor cushions?

Can I order fabric samples before I buy?

Are custom outdoor cushions waterproof?

What's the difference between indoor and outdoor cushions?

Can I leave outdoor cushions outside in the rain or winter?

How do I clean outdoor cushions?

Can I buy just the foam inserts, or just the covers?

Can I buy outdoor fabric by the yard and make my own cushions?

Do you make custom cushions for outdoor sofas, chaise lounges, benches, and wicker furniture?

How long does it take to receive my cushions, and where are they made?

How do FoamOrder's custom outdoor cushions hold up over time?