Couch Cushions Replacements and Custom 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!


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!

Foam meets CertiPUR-US® certification.
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 Tolerances

Custom-cut seats and cushions have dimensional tolerances according to the "Custom-Cut Cushions" section of our Dimensional Tolerances table. If your project requires a tighter tolerance, Contact Us for more information about machine cut custom items.

Largest Solid Sheet

The largest solid size available is 76" x 82". When any one piece of foam is ordered larger than that, it will be glued together with another piece. There are no additional gluing charges for oversized cushions.

Largest Solid Thickness

The 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

Great Customer Support
JAN | May 18th, 2022
Not only did the foam arrive on time but it was perfectly cut & wrapped. I called customer support before ordering & to confirm delivery & the staff are incredible--educated me on details, made suggestions, inquired about my project so I'd get the correct item. I don't know if you'll get this kind of support from local companies, but those near me were not nearly as helpful or cost effective. I've recommended the company multiple times already & will definitely use them again.
Sofa cushions
Beverly Lemcool | May 18th, 2022
Looked at endless sites for replacement cushions. Finally decided Foam Factory (foam by mail) had great pricing and just what I THOUGHT I needed. I was quite pleased to find I made the right decision. My cushions arrived timely, as promised, cut to my specifications, Dacron wrapped, and fit the cushion covers I had just made perfectly. I was really nervous about the fit since I made the covers prior to arrival of the foam and dimensions needed to be exact. Not only were they perfect, the foam is sturdy but comfortable. I couldn’t be happier. If I ever need this type of product again, there is no doubt that I will return here.
Perfect Fit
Travis Ng | May 17th, 2022
The instructions were clear and I was able to get a new cushions for an heirloom sofa. The Lux foam was much firmer than expected, but after a day, the foam felt great. Would definitely order more in the future if needed.
Excellent and Easy!
Kay | May 17th, 2022
Needed 2 cushions replaced in my couch after we realized we only sit in the same spots. I went to multiple upholsterers for pricing and found this place online. I measured exactly as they told me, and was amazed at how perfectly the fit in to our couch cushions. I would highly recommend! The website is easy, the pricing is insanely reasonable and the quality it great!
Excellent resource for replacement cushions
Barbara Stoughton | May 16th, 2022
Have an Ethan Allen chair I cannot let go of, but seat cushion needed replacement. Found this site online; so happy to have found it! My cushion is excellent. It was too big, but that was my fault in measuring, not the fault of foam by mail. If I need replacement cushions in future, I will definitely order from here, and I would recommend them. Measure carefully and pay attention to their helpful hints.
Not cut to size
Chris searson | May 16th, 2022
Ordered 23x21x3, received 24x21x3, so I had to cut the extra inch off myself Wonderful foam though
good value
Brandon | May 15th, 2022
I needed a custom mattress to use on a platform in my truck bed on overland trips so I emailed their customer service and got a very quick reply that was helpful so I was able to order what I needed quickly instead of trying to trade emails over days or weeks. Mattress is exactly what I wanted. Thanks!
Perfect restoration
Gary z | May 12th, 2022
Adds 5 to 7 years of life to a wonderful sectional sofa! Great product, great service!
Sofa Cushions
Darlene Bridges | May 12th, 2022
These are absolutely perfect. Fit is perfect and the density is just what I needed. Thanks.
I’ll give 5stars to attention and products
Milan Upholstery | May 11th, 2022
I’m 💯 % satisfied with your product it arrived on time and nicely wrapped. 2.8/50 is just a great foam to work with. You’ve got my business and more orders coming in near future. José
Great quality for the price
Luric | May 10th, 2022
These are better than the original cushions that wore out in 2 years. Nice and firm. Feel like they can last for years before needing replaced!!!
Cushions with support
Christine Laird | May 10th, 2022
Finally - a cushion that provides firm support! Have been searching for an insert cushion that provided support and one where I didn’t sink to the bottom of the chair when I sat. These were EXACTLY what I’ve been looking for. If you want firm support, you cannot get with ordinary store-bought cushions. So I substituted these for my cushion stuffing that came with my original cushions. Total support and now I do t need to sit on an extra pillow for comfort and support.
Couch cushions
Barry Morse | May 9th, 2022
Foam cushions fit perfectly----it's like a brand new couch
Outstanding Service and Product
Brenda Malone | May 9th, 2022
I ordered a custom-size replacement foam cushion for my chair. I had never done this before, so I was hoping that I did everything correctly. Turns out, the process was easy to follow and the cushion was delivered in less than one week. And it was perfect. The communication was very good, I was kept up-to-date on the entire process. Highly recommend Foam By Mail and I will be back for more.
100% Satisfied
Debbie Knoll | May 5th, 2022
I can’t say enough about this company! Our experience was fantastic due to their product and instructions on how to measure. We followed the instructions and received our cushions in perfect size. The foam is great quality, and packed nicely for shipping! It took a little over a week from ordering to receiving 5 large cushions for our sofa’s. The website is super user friendly! I highly recommend them and will use them again!
Very happy with my purchase!
Laura Napolitano | May 5th, 2022
I’m really pleased with the quality of the replacement foam I purchased for my loveseat. It looks good as new now, and I’ll definitely be purchasing again when I need it for other chairs in my home!
Great service
Susan Halvorson | May 4th, 2022
Highly recommend!
My couch is great again!
Tony | May 4th, 2022
Thought my couch was done for after years of kids jumping on it. Amy M. was SUPER friendly and helpful through the entire process. She sent us samples which helped us choose which foam type to go with. Can't say enough good things about this company!
Purchased couch and loveseat cushions
Allen Collins | May 4th, 2022
Custom chair cushions
Jenn | May 3rd, 2022
Ordered custom measured cushions for my hand me down leather couch and loveseat. Wow wow wow. They came perfect as needed and turned what were the two most uncomfortable pieces of furniture I’ve ever sat in to like new. Saved so much money (I was about to just buy new furniture they were THAT uncomfortable), the shipping was fast, and the quality was excellent. Could not have had a better experience.
sue E browning | May 2nd, 2022
Our couch is revived
Chris | May 2nd, 2022
Replacement cushions for our 10 year old couch arrived in the correct size and fit great. Nice to extend the life of our old couch another decade!
Foam camper mattress
EJ | May 2nd, 2022
I love the new mattress for my cargo trailer. It fits perfectly and it super well made. The gray and white striped cover is perfect for my gray interior.I would definitely buy again and recommend to friends.thanks!
Shannon M | April 27th, 2022
Ordered new chair cushions, high density for a firm feel. Very firm. Came perfectly sized based on directions provided on the website. Make my custom chairs like new. Would definitely reorder again. Shipping is via FedEx, which sucks. Packaged well.
Great product and magical customer service
Lori Schwabenhausen | April 26th, 2022
So glad custom is an option because I needed a very unusual size. Product seems great and should withstand time. But y'all, the customer service is magical. Garrett contacted me about my original choice to give me some additional insights and I ended up switching to a different foam. In the past year, I had to lower my service expectations but Garrett has given me hope we can all help each other.
Very pleased.
ML | April 25th, 2022
I was nervous about measuring, the old cushions are about an inch thicker, but the fit well and are firm and comfortable. Thanks!
Glad To Have Found You
Pamela | April 25th, 2022
I ordered a custom cushion cover from another company little did I know it didn't include the foam. Mistake was on me for not doing better research. I ordered a 4 13 127 cover but found out later they did not make to the size I needed. While researching another company was nice enough to refer me Foam By Mail. What I love mostly about your company is you don't have to by a cover. I love the cushion, it is exactly what I wanted. It so comfortable. I will be placing another order soon to replace the cushions on my coach. Great Job! PDH
Amazing quality
Ryan M | April 25th, 2022
Foam is even nicer in person than I expected. Perfectly cut to the dimensions I needed and packaged well. Really helped out my old cheap couch feel even better than new. Definitely recommend.
Very pleased.
Gaye Fahey | April 25th, 2022
The custom cushions I ordered were perfect. I am very happy with my purchase. Also the help on how to measure and which foam was best for my needs. Thank you.
Good product, fast delivery.
Gary | April 25th, 2022
Ordered three couch cushions. Ordering was simple, delivery prompt, and the product is very good. I replaced the aging foam with new, high density foam. The difference is extraordinary.
Bench cushions
Marcia Davis | April 25th, 2022
Extremely pleased with the product. Delivery was fast and arrived in good condition. Will definitely order again for future needs!
Great Results
Jeff | April 22nd, 2022
Very pleased with the prompt service and the quality of the foam. My order was perfect and restored my old sofa back to the day it was delivered from the showroom. I did price comparisons with other similar service providers and found this to be the best price out there. Highly recommended!
Excellent product
Roxanne | April 22nd, 2022
Scary measuring the cushions yourself, but they fit perfect. They are nice and firm and comfortable.
Elizabeth Morrow | April 21st, 2022
Couch cushions arrived quickly and were exactly what we needed. Great quality
Easiest Project
K | April 21st, 2022
These came out great! They were exactly what I needed for my project, because you cut and had an option for the Dacron wrap this took basically no effort on my part! The foam is great and the Dacron was wrapped beautifully!
Better than Original cushions
Patricia M Williams | April 19th, 2022
We ordered 3 replacement cushions for the original cushions that came with our flexsteel couch. These cushions are far better than what we've been sitting on. I would highly recommend this product!
Sara Gary | April 18th, 2022
Order three replacement cushions for our couch. They were 100% what I expected. They are pretty much better than the cushions that came with the couch! Thanks a ton!
Very pleased
Karen K | April 18th, 2022
I had originally bought the most expensive cushion and found it was too stiff. Bought another and went with less firm and it’s perfect! Doesn’t stand out as to hard nextto the other cushions.
Foam cushion
Teresa | April 17th, 2022
I recently ordered a 4” 17x73 Dacron wrapped foam cushion for a mud room bench. I was SO impressed when it arrived! Would definitely use/recommend Foam by Mail again.
Jackie Rich | April 15th, 2022
I was going to DIY cutting and covering the foam for a long bench but this was less $$ and had no waste. It came in quickly and was the perfect size. I definitely “bookmarked” their site for my next project.
The Right Choice!
Dave | April 14th, 2022
Was looking to replace my cushions on my couch. I found Foam Factory and at first I was a bit scared at trying to get the right size. I submitted my order and second guessed myself about the sizing. I contacted Foam Factory and after several emails back and forth, I was confident that I had done everything correctly to their specifications. They arrived sooner than expected and when I placed them inside the covers they fit PERFECTLY! I was so happy with my purchase and the communication with Garrett at Foam Factory. Very comfortable and the price was very affordable. I would highly recommend them if you are looking to replace the foam cushion in any of your furniture pieces.
Good product, great service!
Jessica | April 14th, 2022
I ordered replacement cushions for my sofa, and a Foam Factory representative contacted me to suggest a different density for the product. Their suggestion was most welcome, and the final foam blocks I received are great! I used an electric bread knife to round the corners and edges slightly, and I'm very pleased with the result. Processing and shipping was much faster than expected, and my cushions were replaced in a week. Highly recommend this company.
Anna | April 14th, 2022
Foam cushions with Dacron for my couch arrived exactly as described. The right size, comfort and look to replace the old ones. Much cheaper than other sites and a high quality product. I recommend
Quick turnaround for a custom order. Quality product.
Maureen McCarthy | April 13th, 2022
I ordered 2 custom cut 3” cushions. Turnaround time from order to delivery was faster than expected. Cushion quality better than anywhere else I’ve purchased foam in the past… and for a better price!
Great Product and Service
Mike Campbell | April 13th, 2022
I ordered LuxHD foam to replace travel trailer cushions. Ordering was easy and delivery was fast. I easily used a bread knife to shape one cushion. Very satisfied. I would recommend this company.
Great product and service
Barb | April 11th, 2022
I ordered replacement foam for my daughter’s couch. She is so happy with the new foam. The order was processed in a very timely manner!
Couch cushions
Larry | April 8th, 2022
The replacement cushions I ordered came quickly and are high quality. They make a world of difference in the comfort of the couch.
Becky | April 8th, 2022
I have ordered replacement cushions for my sofa on two separate times. Received both orders very quickly. The product was sized correctly and I was extremely pleased with the quality. I will definitely use this company again and they have my highest recommendation.
3 cushions for my couch
Julie | April 6th, 2022
We are sooo happy we used foam factory to replace the cushions on our couch. I had back surgery three years ago and needed a firmer cushion for our couch. We ordered the cushions and Garrett contacted me to let me know that the cushion we had ordered was very firm and wanted to make sure we understood that before he processed our order. He really impressed us that he cared that we would be getting what we really needed. I will order from Foam Factory again and tell other people about them. Thanks Garrett for all your help!!!!
Great product
Nancy Vondran | April 6th, 2022
This is the second time I have placed an order. Great service, perfect measurements and fast delivery.