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Build a DIY Beanbag with Our Shredded Foam

Homemade beanbag chairs and foam sacks have been growing in popularity recently, as people begin to tread farther off the beaten DIY project path. Whether they’re for a child’s bedroom, a school’s playroom, or a family’s theater or game room, beanbags built to suit your preferences and style can give you comfort and satisfaction in ways few other pieces of furniture can. And for people who want those benefits without the hassle and markups of big-box stores, DIY beanbag chairs offer a terrific solution through our collection of shredded foam. This foam has many uses, and one of those is as a bean bag chair filler.

Foam Factory's passion suede beanbag cover selection
Foam Factory’s passion suede beanbag cover selection

The Limitations of Beanbag Repair

The size of beanbags is what stifles many attempts to build or repair them because sourcing materials in the quantities necessary can quickly turn a simple project into a costly one. Just finding enough foam stuffing to fill a 6’, 5’, or even a 4’ beanbag can be a headache, without even touching on how cost-ineffective purchasing small bundles of material becomes. The key is finding a retailer who offers affordable bulk orders while maintaining a retail side to their business, so individuals can place large, one-time orders. Fortunately, this is FoamByMail’s specialty. We offer four different shredded foam types in bulk sizes that are perfect for a DIY beanbag, re-filling, or firming up existing beanbags.

Shredded conventional foam is sold in 36” x 36” x 48” sacks, weighing approximately 30 lbs. apiece, and featuring an average 2 lb. density polyurethane foam. This foam is also sold in the 15” x 15” x 72” size, weighing approximately 8 lbs. Shredded memory foam is also sold in 15” x 15” x 72” sacks which weigh about 15 lbs. These two foam types are ideal for filling beanbags/foam sacks, and each offers its own set of benefits, such as the temperature-sensitive contouring of memory foam and the plush cushioning of conventional foam. No matter your comfort preferences, one of these types of shredded foam will help you create the perfect DIY beanbag chair.

Making Your Beanbag Chair

Now that you know where to find the perfect shredded foam filling, it’s time to make your beanbag chair. Here are the materials you’ll need:

  • Fabric: Choose a durable fabric that suits your aesthetic preferences and is strong enough to withstand regular use, such as denim, canvas, or upholstery-grade material.
  • Thread: Select a high-quality thread that matches your fabric’s color.
  • Shredded Foam Filling: This is the heart of your beanbag chair’s comfort. Foam filling offers exceptional support and adaptability, so it’s perfect as a bean bag chair filler.
  • Zipper: A heavy-duty zipper will allow you to refill and adjust the foam as needed.
  • Needle and Pins: Sewing essentials for assembling the fabric pieces.
  • Measuring Tape: Accurate measurements are essential for a well-fitting beanbag.
  • Scissors: To cut the fabric to the required dimensions.
  • Sewing Machine: While you can sew by hand, a sewing machine will make the process faster and more efficient.

And here’s a step-by-step guide to making your chair:

  • Step 1: Design Your Beanbag Chair
    Decide on the dimensions and shape of your beanbag chair. Standard beanbags are usually spherical or pear-shaped, but you can get creative and choose a design that fits your space and style.
  • Step 2: Prepare the Fabric
    Using your measuring tape and scissors, cut your fabric into two identical shapes according to your chosen design. Remember to account for seam allowances. These fabric pieces will form the top and bottom of your beanbag.
  • Step 3: Sew the Zipper
    On one of the fabric pieces, mark the area where the zipper will be placed. Sew the zipper securely along this mark. This will create an opening that allows you to add or adjust the foam filling.
  • Step 4: Sew the Fabric Pieces Together
    With the zipper facing down, align the fabric pieces with their right sides facing each other. Pin them together along the edges, leaving a small opening at the opposite end of the zipper for turning the beanbag right side out. Using your sewing machine, sew along the edges, leaving a seam allowance of about half an inch. Reinforce the seams at the corners and around the zipper area for extra durability.
  • Step 5: Turn It Right Side Out
    Through the opening you left, turn the fabric right side out. You’ll now have the outer shell of your beanbag chair.
  • Step 6: Fill with Foam
    Now comes the exciting part – filling your beanbag chair with foam. Begin by inserting a funnel into the zipper opening and carefully pouring the foam into the bag. Fill it to your desired level of comfort, keeping in mind that the foam will compress slightly with use.
  • Step 7: Close the Opening
    Once you’re satisfied with the amount of foam filling, carefully zip up the opening. Ensure that the zipper is closed securely to prevent any foam from escaping.
  • Step 8: Shape and Fluff
    With your beanbag chair now filled, take a moment to shape and fluff it. Gently shake and knead the chair to distribute the foam evenly and achieve your desired level of comfort and support. Now you’ve successfully crafted your own DIY beanbag chair!

Beanbag Covers: an Alternative Option for Non-Sewers

For most people building their own beanbag chairs, acquiring the stuffing material is the hardest part of the equation. However, some individuals may not have the confidence in their sewing skills to create something durable enough to hold up in the long term. Others may have a perfectly comfy beanbag, but over time the cover has been stained or damaged. For those looking for the perfect cover for their DIY beanbag, we offer completely customizable foam sack covers, in vibrant colors with terrific quality.

Proudly hand-sewn in the FoamByMail shop, each of our beanbag covers is made to last for years and looks great doing it. Made of luxurious and soft passion suede, beanbag covers are available in 12 colors and 6 standard sizes: 3’ and 4’ round shapes, and 5’, 6’, 7’, and 8’ rectangular shapes. Each cover features a heavy-duty zipper covered by protective flaps to keep the user comfy and the beanbag chair attractive. Learn more about our foam sacks sizes & prices on our website.

In addition to our standard offerings, we will custom-make covers in many non-standard shapes and sizes for special orders. And for people who aren’t crazy about passion suede, we also have 100% cotton twill fabric in eight rich colors that can also be made into a custom cover. For those who have the foam filling and the outside cover taken care of, we even offer pre-made black twill inner-liners in six standard sizes. These allow you to remove outer covers for laundering without having to deal with the hassle and mess of loose foam filling everywhere.

Relax and Unwind in Your DIY Beanbag Chair

Crafting your own homemade beanbag chair is a rewarding experience that not only results in a comfortable piece of furniture but also allows you to tap into your creativity and craftsmanship. Here at FoamByMail, we can accommodate your beanbag needs no matter what they are. So whether you’re looking to build a completely customized beanbag chair, or you only require a single beanbag or foam sack component, you needn’t look further than FoamByMail!

76 thoughts on “Build a DIY Beanbag with Our Shredded Foam”

  1. I am afraid that filing my 5 foot bean bag with shredded foam will make it very heavy as opposed to traditional polystyrene “beans”. What’s the difference in manageability between the two?

  2. Yes, the weight of shredded foam is about 1.5x to 2x the weight of polystyrene beans. However, polyurethane foam has the advantage of longer life over polystyrene beads. Usually double the life span.

  3. How can I figure out how much foam I’ll need to refill a beanbag chair?

  4. I am purchasing three bean bag chairs measuring 32x28x25. I know from the reviews these chairs will go flat and need refilling very soon after we start using them. Would you please make a recommendation on which shredded Foam would be best for us to purchase from you, as well as how much to purchase? We don’t care about the weight, just about the chairs being amply fluffed and long lasting. Thank you!

  5. i am looking for polyuthereum foam for my xl bean bag. I am not sure how much will i require.

  6. Our regular size bag fills about 5 cubic feet while our large size bag fills about 15 cubic feet. If you send over a size then I can approximate how many bags you will need.

  7. I have a “Giant Bean Bag”. It’s measurements are 210x210x90cm. Can you please tell me how much I need, and your recommendation on which filling would be best?

  8. I have a 7ft x 3ft x 3ft bean bag chair, how much fill to fill it? I estimate 5 large bags?

  9. I need foam for a 210cm x210cm x 90cm. Charcoal shredded foam. How m7ch do I need

  10. Can you tell me how much shredded form to fill a bean bag chair. It is approximately 48” round and 27” tall. Also, if I were to use the poly beads, how much of that would I need?
    Can I mix the two? Thank you!

  11. I bought a 7′ bean bag chair, pretty sure its round in shape. How much foam to fill that up? Preferably in cubic feet, thanks.

  12. Hello, our bean bag cover is 41″ in diameter. How many pounds of shredded memory foam would we need?
    Thank you!

  13. hi I have one of those 6 foot been bag lougeer I am looking to replace the guts. Can you please tell me how much will be needed of either kind. I also need a liner. as this one did not come with one.

  14. Hello! I’ve always wanted to make a large size bean bag of sorts. I have a Cal King size foam mattress topper that I wanted to cut up and use as the inner. How big should I be cutting these pieces of foam? Do you recommend using this type? I would love to purchase a cover to use. What size cover would I need for this much foam?

  15. How much filler do I need for a 7ft 183 cm bean bag that I bought from hotkicksoutlet.com?

  16. Can I mix shredded foam with the poly beads in my bean bag chair? Or do I only use one or the other?

  17. How much shredded foam do I need for a 41″ in diameter round beanbag? Thank you.

  18. I have an 8 ft bean bag. How much foam would I need? Is there a benefit to mixing the shredded foam and shredded memory foam?

  19. I have an ultimate sack that’s 4×4 that I need to completely replace the foam in.How much would I need?

  20. How much foam would fill a 4ft x 4ft x 2ft bag? Also do you sell memory foam or just regular foam?

  21. I have getting four bean bags showing sizes of 39″ X 47″. These are pictured as typical round type bags with the top showing a handle. These are for teens bedrooms and will be shipped. Could you please let me how which foam and how much foam is recommended. Regards

  22. I would like to fill a 7ft bean bag with foam. How do I order this and what would the cost be? Also, where are you located?

  23. I need to fill a full size mattress that folds and tucks into a chair cover. The measurements of the mattress are 54x75x8 inches. I’ve calculated that I will need a little less than 40lb of conventional foam. Does this sound correct?

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