Custom Cut Seat Cushions
Use our custom cut cushion service to order replacement seat and sofa cushions to breathe new life into your furniture. Simply select your shape and enter in the dimensions, foam type(s), and quantity, and our team of specialists will craft foam cushions tailor-made to your specifications.
Don't see your shape listed below? We can make nearly any custom shape to special order. Contact Us for details.
Click on a custom cushion shape to get started!
Features
Video: Foam Types for Seats and Cushions
Notes
There is no denying that foam is a versatile material you can use for just about anything. While it can be used for a range of applications in both commercial and residential areas, one of the most common uses is seating cushions.
With our selection of couch cushions replacements and custom cushions, find the perfect shape for your needs at an affordable price. When a sofa has old, flattened cushions, it can make the seating less supportive and comfortable. Most cushions tend to lose their appeal over time and become relatively thin. The best way to remedy this is with our couch cushion foam inserts. We have a wide selection of foam types and styles for you to choose from with our selection of affordable custom cushion options.
Have an unusual furniture set? It’s easy to get the customized seating you need! Contact Us and we can help you get started!
Return Policy
Custom cushions cannot be accepted for return unless there is a product defect or a manufacturing error. Please see our Return Policy for more information. If you have questions concerning our return policy, please Contact Us before placing your order.
Manufacturing TolerancesCustom-cut seats and cushions have dimensional tolerances and physical property tolerances according to the "Custom-Cut Cushions" section of our Manufacturing Tolerances table. If your project requires a tighter tolerance, Contact Us for more information about machine cut custom items.
Largest Solid SheetThe largest solid size available is 76" x 82". When any one piece of foam is ordered larger than that, it will be sent as SEPARATE UN-GLUED PIECES. We will NOT glue the foam together. If you wish to join the pieces yourself, spay adhesive is available for purchase. View our spray adhesive options.
Largest Solid ThicknessThe largest solid thickness available is 6". When any one piece of foam is ordered at a greater thickness than that, it will be glued together with another piece. Up to 8" thickness, there are no additional gluing charges. For thicknesses greater than 8", an additional gluing charge will apply.
Frequently Asked Questions
How do I order custom cushions?
To order a custom cushion, start here on our Couch Cushion Replacements and Custom Cushions page. Next, choose a shape that best fits the furniture’s original cushion. Click on the shape, and you’ll be taken to the shape’s page. You can enter the size and thickness you need on that web page and then click on the next step. If you are unsure how to measure, we also have a convenient and easy-to-follow PDF guide on How To Measure.
Who makes custom cushions?
Custom cushions are made right here at Foam Factory, Inc. headquarters in Southeast Michigan. They are cut with a wide range of today’s most innovative technology.
How thick should a bench cushion be?
There is no standard thickness for cushions. Typically, the thickness you want to go with would be in accordance with the cover for the couch or bench cushion.
Write a Review
Sprout | February 17th, 2026
I have purchased several times. The foam and service is great. Price as well.
Katherine Stevens | February 17th, 2026
I appreciate Foam Factory because even the projects that only require small amounts are treated with the same care and professionalism that a large order would. I needed a few extra inches to finish the pet couch I was crocheting, and they actually cut the foam to the exact, small sizes that I needed! That's how a business keeps customers coming back!
Veronica Egan | February 17th, 2026
This is our second order placed with Foam Factory, my boyfriend ordered some standard cushions and I now ordered an “L” shaped one for our sectional- they came out better than expected, it gave our old couch a new life we love to relax on our couch again, and my back isn’t killing me anymore. It is a fantastic solution to not have to buy a whole new couch, and it’s been a significant quality of life improvement. Thank you!
Pat | February 17th, 2026
Ordered 3 custom cushion replacements for our sofa. Followed measuring instructions and cushions were a great fit. Sadly, following the recommendation on the site for the type of foam suggested for sofa cushions the Lux Quality High quality was ordered and the cushions are very stiff and much to hard to be comfortable for our sofa. Unfortunately, returns are not available. Trying a suggestion from customer service to see if we can salvage them. To be determined if it works.
Randi M | February 9th, 2026
Excellent customer service handling questions and solutions
P.H. | February 6th, 2026
This order was to replace existing worn sofa cushions. Instructions for measuring were very clear and resulted in receiving cushion of exact measurements ordered. Quality of cushion is superior, service was flawless. Thank you for a most pleasant experience.
Marcy | February 5th, 2026
Fit was perfect. I was a bit disappointed that they were so firm. The Dacron wrap did not make them feel any softer . Great service .
Tom | February 5th, 2026
We were ready to throw out our 3 year old couch because it had become so uncomfortable. I decided to try new foam and it totally transformed the couch. It's finally comfortable again, and the foam has a much longer lifespan than the 2-3 years of our original foam.
Bruce Eaton | February 5th, 2026
The question was whether to buy a new sofa or just replace the old cushions since it was difficult to get up once being seated. We chose the cushion route and purchased the most dense cushions which provides comfort without feeling like you are sitting on a rock.
Debra Kronenberg | February 5th, 2026
I replaced the pillow in a very old needle pointed piano bench cushion and I had questions before undertaking such a delicate project. Customer service was extremely helpful and gave me the confidence I needed to complete the project. It turned out just as I wanted.
Fred | February 5th, 2026
Love these! Produced beautifully!
Kiera | January 25th, 2026
The sight helped me decide the firmness and how to measure. It was easy! The cushions came fast, and they're perfect! Sitting on them now!
K. Gallagher | January 24th, 2026
Perfect for the banquette we built. Very comfy and holds its form.
Natalie | January 24th, 2026
Needed to replace back cushions for my couch. Placed the order, customer service e-mailed to note this might not be the best type of foam and held my order till I could make a change. Super appreciated they did that instead of just sending the wrong thing! Will definitely use them again.
D | January 23rd, 2026
Can't beat the quality, speed an cost of these cushions.
Misty T | January 23rd, 2026
We save our heirloom couches by ordering cushions to replace the ancient stinky ones. The new cushions arrived in a timely manner and were measured to my specs I gave them.
maggie | January 23rd, 2026
Very happy with the 2 new foam cushions for the sofa. MADE IN THE USA🙂👍what I was looking for. The web site is user friendly; like in person shopping for what you are looking for. Many options and thorough, good descriptions for the various shape and types of foam cushions.
I would highly recommend FOAM BY MAIL for foam needs.
Reen Behringer | January 23rd, 2026
I needed foam rectangular blocks to use for custom covers for my little dog to get on couch and be stylish and the foam fit perfectly and arrived fast and easy ordering process!
Ms. Z | January 15th, 2026
I love these cushions. Bought on blind faith and you couldn't return them but they renewed my couch and I didn't have to buy a new one. They did a great job. I will definitely use them for other furnishings.
Blythe | January 9th, 2026
Kathleen reached out to make sure I got the best product for my needs after I placed my order. I was very happy with the customer service, quick turnaround and high quality product!
Bernice | December 28th, 2025
So far I am very pleased with the firmness of the foam I ordered. I would recommend Foam Factory to others
Mike | December 26th, 2025
These cushions are excellent. The process to purchase was easy and quick.They even contacted me with a recommendation that I might want to change something. Helped me greatly
Rick | December 26th, 2025
We needed cushions for our couch and found foam by mail. We received these cushions in no time, replaced old ones and are very pleased with them. Measurements are perfect and cushions are good and sturdy. Will buy again. Totally satisfied.
Maryann Kirk | December 26th, 2025
Had a special size made with striped mattress cover to fill a gap at the head of my new bed. Turned out great,
As always very well made, and precise measurements. Thanks!
Rachel | December 26th, 2025
I ordered cushion inserts for chair covers!Precise cut for each measurement and perfect fit!The quality is very durable! Customer service was very helpful when I needed to add to my order and with my qualifued discount!
George Cummings | December 26th, 2025
I ordered high end very hard lux foam to replace old loveseat cushion foam that deteriorated over time. I received a call from customer service to make sure my request was valid, since the foam is very hard. Per the rep, as hard as sitting on a park bench. I still kept the order, but found out the next day that I had mis-measured. When I notified customer service they corrected my order immediately and I received the new cushions fairly quickly. Turns out they are exactly what I wanted and needed. Kudos to the Foam Factory and staff.
Daniel | December 26th, 2025
The quality of these cushions are excellent I will definitely buy again the measurements were perfect thank you.
Matt | December 25th, 2025
We keep upgrading our furniture with Foam Factory foam! Always great products and service!
D S | December 20th, 2025
Was needing to replace couch seat cushions and gave this a shot. Good quality at a good price. Would recommend.
James Schoner | December 17th, 2025
We suffered from worn couch cushions and decided to fix the situation.
What an extremely satisfying experience Foam Factory provided to us.
Highly recommended !
Sandy | December 12th, 2025
We went from sitting on stacks of pillows to complete comfort! Our camper came with dinette cushions that sank under our weight, so that we felt like we were sitting on wood. A friend recommended FoamByMail, and I checked it out. Not sure what I needed, I called customer service, and they answered all of my questions. When the package arrived, I quickly made the switch, and we are now able to keep the pillows for decoration, and the new seats are absolutely perfect. We are also full-time RVers, so comfortable seats and shipping are a high priority. FoamByMail fit the bill just right! Thank you!
Dustin Paulson | December 12th, 2025
I ordered two replacement seat cushion foam inserts for our two mission recliners.The foam arrived in a reasonable time frame, and was apparently vacuum bagged at the factory, then wrapped with plastic film to hold into a size that would fit the sipping box. In order to get the two cushions separated for installing into the cushion covers the plastic film needed to be removed, which allowed the cushions to return to their normal size and shape. Getting the cushions installed into their chair covers in their expanded state would have been very difficult, so I ended up purchasing some vaccum storage bags, and putting each cushion into it's own bag, and vacuuming it down to about half it's expanded size. I was then able to easily get the cushion into its chair cover before opening the seal on the bag to let it expand and fill the space inside the cover. I was then able to cut the exposed side of the vacuum bag and push it down, and around the cushion within the cover, and then pull it out from the other side, sacrificing the vacuum bag. This worked well, but it cost a few dollars for the jumbo vacuum storage bag, and time waiting for them to arrive before I could install the cushions. I would have been nicer if the factory could have shrunk them down in individual vacuum bags for shipment, that we could have used for the installation. I'm sure that with their volume, the bags would have been a negligible cost, and make it lot more convenient for the customers installation process.
Lonna | December 12th, 2025
We are very pleased with our purchase and we would highly recommend your company for anyone looking for custom made cushions.
Patricia | December 12th, 2025
This was my second order from this company. The first order a couple of years ago, wrapped in Dacron was wonderful. This one the Dacron was not as tight and has not stayed together on the sides. Disappointed but the foam is wonderful
Danielle | December 12th, 2025
Had our couch for almost 10yrs. The old cushions were so thin that it would be painful to sleep on. I purchased the cushion, lux foam - Regular. These are so firm that you would not even slouch sitting down. And there are no longer any gaps between the cushions. I plan on getting more cushions for the downstairs couch we have.
Kathy Dana | December 12th, 2025
I loved that I didn’t have to spend money on a whole new couch! The only thing different I would do is order a little less firm. I ordered the medium-firm, I should’ve ordered plush. But other than that it is great!
Lori | December 12th, 2025
Replaced our 1 year old (sagging) couch cushions with HD36 foam, and it's like having a brand new couch! Did my homework online first, noted that people had great experiences with Foam Factory, and I can confidently say they were all accurate. Will be coming back here again when the need arises. Yeah, it's a bit of a wrestling match to get the new cushion into the covers, but it's worth it. Highly recommend!
Sitting Comfortably | December 12th, 2025
Recently ordered new Lux foam for my sofa cushions and I am SO very happy with them! The clear instructions on how to measure along with videos was great! The quality of the foam is top notch. The new foam brought my cushions back to life. Shipping and processing was also really fast and great value for the money.
Caitlin | December 12th, 2025
I ordered a high-quality foam cushion with dacron wrap to replace the old down-filled cushion on a Sheraton sofa. Couldn't be happier with it! Gave the couch new life. I was quoted over 3 times as much by a decorating store to have them do the same insert. Would order here again.
Ruttanatip | December 5th, 2025
Perfect fit and great quality foam cushions. Saved us a lot of money from buying a new living room set.
Nav Khehra | December 4th, 2025
This was my first time ordering from Foam by Mail and I have been so impressed with both customer service and product. I contacted them via email prior to submitting an order to ensure that I was selecting the correct type and measuring it correctly. I received a response the very next morning. The product arrived on time and was a perfect fit! I'll definitely be ordering again as they customize various shapes and sizes!!! I am so glad I found this company!
SteveB | November 29th, 2025
I've ordered multiple times for different projects. Foam by Mail/Foam factory has excellent products. These last cushions brought our favorite old couch back to life. Don't go too aggressive on firmness, I went high end high density the first time and the couch was not comfortable, the stand foam cushion is perfect.
Howard | November 26th, 2025
We needed to fix up our couch so we ordered a new pad for the couch and it was a good fit and easy to make little adjustments for our couch. We cannot be happier with the new pad and it was easy to order and delivered quickly to so if you need a pads or anything else we can highly recommend them for your needs
Michael Tyree | November 25th, 2025
Cushions fit perfectly! Exact to my measurements! I have bought several cushions over past couple of years. Always perfect fits and they are holding up great. Should last for a lot of years to come. Fast service and fast shipping! Thank you so much. This is the best place to buy cushions. I highly recommend! High quality and fast service!!
Sheila | November 25th, 2025
This is the 2nd time that I ordered cushions for my sofa. The first ones were so great that I knew just where to go. This order, just like the first, fit the cushion covers perfectly. The sofa is old but built so well that I just cannot part with it. Foambymail goves me that option.
Jeffrey Patterson | November 21st, 2025
I ordered 5 couch cushions and they are great. It was easy to order and came quickly. I have 3 more cushions to order, and the couches will be done. This is a great company to do business with.
Peter Coleman | November 20th, 2025
I didn't really want to buy another love seat just yet. I've tried other foams from different sources and was leery of wasting time and money on a cushion that didn't work. The website was very helpful and detailed. The cushion fit perfectly. Now I've got to buy a second one to complete the job. Thanks.
Bonnie | November 13th, 2025
I ordered two cushions for our leather couch and they are great. Very nice quality and easy enough to order. The website is very helpful and I received the perfect fit and comfort that we needed. I will be ordering more soon!
Mary Van Haaren | November 13th, 2025
Even though I’m local, I love the option of ordering on line and picking it up when it’s ready -
Douglas | November 13th, 2025
I ordered two cushions. They were two separate densities. They are exactly what I needed for the Morris style chair that I just built. I couldn't be more pleased. I highly recommend this company for their quality product and quick fulfillment of my order.
