FoamOrder makes custom cushions to your exact measurements for sofas, sectionals, benches, chairs, window seats, patio furniture, boats, and RVs. Choose from over 30 foam types and more than 1,000 fabrics, or order foam only, and we cut every cushion to order within 1/4 inch in the U.S. Whether you're building seating from scratch or replacing worn cushions on furniture you already love, you can design and order yours online.

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Custom Cushion Reviews from Real Customers

Butch B
Maplewood, NJ

Product featured Replacement Couch Cushions

Jennifer S
Lake Frederick, VA

Product featured Custom Outdoor Seat Cushions

Tiffany W
West Des Moines, IA

Product featured Custom Bench Cushions

Andy L
Houston, TX

Product featured Custom Cushion Covers

Kat T
San Diego, CA

Product featured Custom RV Mattress

Celia A
Boulder, CO

Product featured Replacement Sofa Cushions

Kelly P
Myrtle Beach, SC

Product featured Custom Outdoor Lounge Cushions

Lynn F
Aberdeen, NC

$Organic natural latex foam sheet$ Product featured Organic Latex Cushions

Deanna S
Delray Beach, FL

Product featured Custom Outdoor Daybed

SoRelle G
Charlottesville, VA

Product featured Custom Dining Bench Cushions

John & Pam G
Orlando, FL

Product featured Couch Cushion Foam

Erin B
Albany, OR

Product featured Replacement Back Cushions

Priya K
Brooklyn, NY

Product featured Custom Dining Nook Cushion

Start Here: Choose Your Foam 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.

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!

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

Custom Cushion Options

Every FoamOrder cushion is built from a handful of choices: the shape, the foam, the wrap, the cover, and the finishing details. Open any step below to see your options and which ones work best for your furniture.

Shape & Size

30+ shapes · any dimensions · cut within 1/4 inch · custom patterns

Choose from more than 30 cushion shapes and enter your exact width, depth, and thickness. Nothing is rounded to a stock size, and every cushion is cut to order within 1/4 inch of the dimensions you give us.

Rectangles and squares cover most sofa, chair, bench, and patio seats.
L-shapes and T-cushions, straight or curved, wrap around chair and sofa arms. See L-shaped cushions.
Trapezoids and polygons fit angled bay windows, wicker frames, and tapered chair seats.
Rounds, wedges, and bolsters suit stools, backrests, and daybeds.
Multi-piece sets keep seat and back cushions, or chaise lounge sections, matched in thickness and fabric.
Pattern Shape handles anything else. Trace your old cushion or the seat itself and send us the template.

Browse every option on our cushions by shape page, and see our How to Measure for Foam Cushions guide before you order.

Foam Types

Polyurethane · organic latex · outdoor foam · memory foam

Foam is the part of a cushion that wears out, so it's the choice that matters most for how long your cushions last. Density (lb/ft³) drives how well the foam holds its shape over the years, and firmness is rated by ILD (Indentation Load Deflection). The higher the ILD, the firmer the seat.

Polyurethane

$Organic natural latex cushion foam$

Organic Latex

Open-cell quick-drying outdoor cushion foam

Outdoor Foam

Memory Foam

Foam line	Density (lb/ft³)	Firmness (ILD)	Expected life	Best for
EverFlex	2.6 to 2.9	24 to 54	15 to 20 years	Everyday sofas, chairs, and banquettes
DuraFlex	2.2	30 to 50	Mid-range	Regular use at a moderate price
EconoFlex	1.8	25 to 55	3 to 5 years	Guest rooms and occasional seating
Organic Latex	5.9	25 to 45	15 to 30 years	Daily use and all-natural builds
Outdoor foam	1.8	25 to 45	15-year limited warranty	Patio, pool, and boat seating
Memory foam	5.3	13	Top layer only	A soft comfort layer over a firmer base

Our indoor polyurethane foams are CertiPUR-US certified and made without fire-retardant chemicals. Organic latex cushions are GOLS-certified, and our outdoor foam is a dry-fast reticulated foam that drains and air-dries instead of holding water.

Memory foam sinks too far to use on its own. To build a layered cushion, call us, or order both pieces and ask us to glue them together in your order comments. Want to feel the difference first? Order foam samples.

Which Foam for Your Furniture?

Typical thickness and the most popular foam for each type of seating

Two rules cover most decisions. Choose a better foam for seating that gets used every day, and match firmness to thickness: thin cushions need firmer foam so you don't feel the frame, while thick cushions can go softer. People over 200 pounds should step up to a firmer foam to prevent bottoming out.

Furniture	Typical thickness	Popular foam	Notes
Sofas & sectionals	4 to 6 in.	EverFlex V44 or Latex N36	Add a down envelope for a plush, sink-in feel.
Armchairs & club chairs	4 to 6 in.	EverFlex V44	A double Dacron wrap gives a full, crowned look.
Dining chairs	2 to 3 in.	EverFlex V54	Keep it flat and tailored. Skip down here.
Benches & banquettes	2 to 4 in.	EverFlex V54 or Latex N36	Everyday seating, so choose a long-lasting foam.
Window seats	2 to 4 in.	EconoFlex C33 or EverFlex V44	EconoFlex works for light use. Go EverFlex if it's a daily reading spot.
Back cushions	Match the seat	EverFlex V24 or V34	Backs feel best a step softer than the seat.
Patio chairs	4 to 5 in.	Outdoor 33	The most popular outdoor choice.
Outdoor deep seating	5 to 6 in.	Outdoor 45	Firm support for deep sofa and sectional bases.
Chaise lounges	3 to 4 in.	Outdoor 33 or 25	Choose Outdoor 25 for a plusher lounge.
Boats	Varies	Outdoor foam	Pair with performance vinyl covers for seating that stays wet.

Not sure which to pick? Our customer service team can walk you through foam and firmness at (415) 503-9314.

Wraps

Dacron · down envelope · cotton · organic wool

A wrap goes around the foam to round its edges and fill out the cover, so the cushion looks upholstered rather than boxy. Dacron polyester batting is standard and strongly recommended on any cushion with a cover. You can choose a book wrap or all sides, in single or double thickness.

Dacron

Comes in four configurations and suits every foam, indoors or out. A double wrap gives a fuller, crowned look.

Down Envelope

Gives sofas and lounge chairs a soft, sink-in feel and works with all foam types. See down cushions and envelopes.

Cotton batting wrap and zippered cotton case

Cotton or Organic Wool

Natural wraps that keep an organic latex cushion all-natural from the core to the cover.

Covers & Fabric

5,000+ fabrics · foam only · cover only · supply your own (COM)

Stack of upholstery fabric samples for cushion covers

Choose from 5,000+ fabrics from Sunbrella, Robert Allen, Premier Prints, Trivantage, and our own FoamOrder line. For seating that sees sun and rain, Sunbrella and marine-grade vinyl are built for full exposure. Swatches cost $1.99 to $5.99 each, so you can compare colors and textures at home before you order.

You also don't have to buy a complete cushion:

Foam only lets you keep the covers you have and replace just the flattened foam inside.
Cover only gets you custom-sewn cushion covers for foam that's still in good shape.
Customer's own material (COM) means you send us a fabric you love, and we sew the covers from it.

Browse fabrics and order swatches on our upholstery fabric by the yard page, or see everything on covers and fabrics.

Finishing Touches

Welt cording · top stitching · ties · Velcro · hidden zippers

Every sewn cover has overlocked inside seams so the fabric won't fray, plus a flapped, hidden zipper you can place where you like. From there, choose welt cording or top stitching for the edges, and add chair ties or Velcro straps to keep cushions from sliding. Adhesive Velcro is available on request for furniture with nothing to tie to.

Welt Cording

Top Stitching

Ties

Hidden Zipper

Production Time & Guarantee

Made to order in the U.S. · 3 to 14 days for foam · 4 to 6 weeks with covers

Every cushion is cut and sewn to order at our workshop in Northern California, and it ships directly from there.

Order type	Usually ships in
Foam inserts only	3 to 14 days
Complete cushions with sewn covers	4 to 6 weeks

If we make a mistake on your order, we'll remake your cushions and ship them at our expense. Outdoor foam cushions carry a 15-year limited warranty, prorated after 7.5 years, and sewn covers carry a 1-year limited warranty. See our warranty and exchange policy for details.

Ordering in bulk or need a faster turnaround? Contact customer service before you order, and we'll tell you what's possible.

Every one of these choices is yours to set, and every cushion is still cut to order in the U.S.

FoamOrder Custom Cushion Customer Reviews

Custom Cushions

Shop By Custom Cushion Category

Custom Cushion Reviews from Real Customers

Shop By Indoor Custom Cushion Type

Shop By Outdoor Custom Cushion Type

Start Here:

Choose Your Foam Shape

Custom Cushion Options

Shape & Size

Foam Types

Which Foam for Your Furniture?

Wraps

Dacron

Down Envelope

Cotton or Organic Wool

Covers & Fabric

Finishing Touches

Production Time & Guarantee

Looking for Something Else?

Custom Cushion Reviews from Real Customers

Custom Cushion Options

Shape & Size

Foam Types

Which Foam for Your Furniture?

Wraps

Dacron

Down Envelope

Cotton or Organic Wool

Covers & Fabric

Finishing Touches

Production Time & Guarantee