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Build a Beanbag with Foam Factory’s DIY Beanbag Materials

Here at Foam Factory, Inc., we offer many products that can help you over-deliver on a DIY project while staying under budget. From couch cushions, to organization methods, foam products can make your life easier, more comfortable, and more enjoyable. Lately, Foam Factory has seen an increase in a particular DIY project, and felt acknowledging it would benefit the visitors of our blog and Web site.

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

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 are able to. And for people who want those benefits without the hassle and markups of big-box stores, DIY foam sacks offer a terrific solution.

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 material orders. Fortunately, this is Foam Factory’s specialty.

With nearly 100,000 square feet of warehouse space, and bulk orders leaving their doors daily, Foam Factory maintains a level of business that allows them to accommodate individual customers’ requests while keeping prices affordable. Foam Factory offers four different shredded foam types in bulk sizes that are perfect for a DIY beanbag, re-filling, or firming up existing beanbags.

Conventional shredded foam and charcoal foam are sold in 36” x 36” x 48” sacks, weighing approximately 30LB apiece, while 4LB density shredded memory foam is sold in 18” x 18” x 72” sacks which weigh about 15LB. The conventional shredded foam is also sold in the 18” x 18” x 72” size, weighing approximately 8LB. In addition to these plush open-cell foams, Foam Factory also offers shredded polystyrene foam, the filling classically associated with beanbags, in a 12” x 12” x 65” sack, weighing around 6LB. These foam types all offer their own set of benefits: the temperature-sensitive contouring of memory foam, the plush cushioning of conventional and charcoal foam, and the firm resilience of polystyrene. No matter your comfort preferences, one of these foam types will give you the perfect DIY foam sack chair.

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 to their DIY beanbag, Foam Factory offers completely customizable foam sack covers, in vibrant colors with terrific quality.

Stuffing the beanbag liner into its new cover
Stuffing the beanbag liner into its new cover

Proudly hand-sewn in Foam Factory’s shop, each of Foam Factory’s beanbag covers is made to last for years and look 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.

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

Ultimately, Foam Factory can accommodate your beanbag needs no matter what they are. 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 Foam Factory.

In addition to their individual beanbag chair components, Foam Factory also sells complete, ready-to-use foam sacks, able to be shipped right to your door. You can see them Here.

74 thoughts on “Build a Beanbag with Foam Factory’s DIY Beanbag Materials”

  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

  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?

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