Seats and Cushions - Custom Cut

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 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 still seating cushions.

With our selection of couch cushions replacements, find the perfect shape for your exact needs at an affordable price. When a sofa has old, flattened cushions or holes in the originals, it can make the seating less supportive and comfortable. Most cushions tend to lose their cushioning appeal over time and become rather 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 options.


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 tolerence, 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.

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Couch cushions
Nancy | November 13th, 2019
Perfect fit. Great price. Easy directions on measuring for new cushions.
Couch Cushion inserts
DMR | November 13th, 2019
What great service and quality! I cannot begin to explain how much new foam cushions made my worn out coach more comfortable and attractive again! Thank you!
Wonderful experience and product!
John Geis | November 12th, 2019
I knew nothing about cushions, so I followed the measuring instructions exactly and read the foam descriptions carefully. The cushions arrived quickly and I was thrilled that they fit the covers exactly. I didn’t realize quite how bad the old ones had gotten until I sat on the new ones and I could no longer feel the frame of the foldaway bed. Great products, good price – I could not be happier. I’ve bookmarked these folks, so when I next needs cushions, I back.
Gail Goldman | November 12th, 2019
Having never used this site before, I was a little cautious but easy to order, good prices and custom size would be ideal. Ordered piece for my new bench seat in mud room which friend will sew. They called me to make sure I’d ordered the right foam and how nice of them! Proceeded with order and it’s perfect. Friend is making the cushion and I can’t wait! Glad I found this site!
Great stuff
Aaron G Brindell | November 11th, 2019
I've ordered a few different things now, and they have always been great quality, and delivered fast. I won't go anywhere else for my foam needs in the future.
best company on the internet
mk | November 8th, 2019
My favorite company existing. Incredible variety of products, ample customization. Order accuracy and customer support unmatched. I Love you foam by mail.
Inexpensive solution for old chairs
Catherine Vaughan | November 8th, 2019
I have two old arts and crafts armchairs I picked up at fleamarkets. The upholstery andthe cushions were totally gone. An upholsterer said it would cost $250 each to replace the seats. With a screwdriver and a hammer and some pillow shams I bought on Amazon I now have two very comfy beautiful chairs.
seat cushions
joy j | October 16th, 2019
super fast delivery....great product. the cushions fit perfectly, and made my re-upholstering project go so quickly!
New life for RV dinette.
Jan Monger | September 26th, 2019
Extremely happy with my order. Living in a rural community, ordering online saved me from making several trips to search for the right product with correct measurements. Very thankful.
A+ experience
Cheryl | September 25th, 2019
Ordered foam to fill 2 floor cushions. Package arrived much sooner than expected—great!—opened the box that night and foam regained shape almost immediately. Perfect density for my purposes—firm, but with enough give to offer sitting comfort. Affordable and no off-gassing :)
Round Cushion
Susan Shaffer | September 25th, 2019
I bought the round 2x40x40 to put under the cushion of a Papason chair I bought that didn't have enough padding. It really did the trick, and was exactly as described.
Very Satisfied
John McKervey | September 25th, 2019
Dimensions were perfect and foam is very firm and comfortable.
Custom Order
Dawn Andrews | September 18th, 2019
Excellent transaction! Custom order was received much much sooner than projected and it was as ordered :) Would definitely recommend! Actually have.
Great Job
Navid | September 18th, 2019
Good price, on-time delivery, good material
Great Product!
Gale Dickerson | September 18th, 2019
My seat cushion came quickly, and was perfect. The measuring process worked perfectly. Thanks!!
Repeat Customer
penny | September 11th, 2019
Good quality, good prices. Don't purchase foam ofter but each time I've been in the market, I've researched around and have gone back to Foam Factory.
Best of the Best
Bobby | September 11th, 2019
Extremely happy with the product I purchased. The pillows were exactly what I expected. High Quality and Well packaged for shipment. We wanted a stiff cushion and these do not disappoint. Will order again in the future when I tackle another project. Keep up the great work and customer support.
I am happy with my new cushions.
Shannon | September 11th, 2019
I was directed to purchase a cushion from, by my upholstery teacher. I decided to replace my cushions for my dining room set. They are just great. The fit on my seats is excellent. I would purchase foam seats again from
Couch and chair cushions
Sheila | September 6th, 2019
I have ordered custom cut and Dacron wrapped cushion three separate times. I was surprisingly pleased with the selection and ultimately the quality of these cushions.
Custom Cushions
Lisa B. | September 6th, 2019
I ordered custom cushions and my leather sectional is like new! The cost was reasonable and the foam is high quality. Will definitely use the Foam Factory for all my cushion needs.
Great resource
Michael Murphy | September 6th, 2019
We just moved and I haven't been able to find an upholsterer yet and needed new cushions for some chairs. I found several sites that offered custom cushions, but offered the best pricing and the best measuring. They offered the rounded T-Cushion and 5 points of measurement, while others only offered 3 or 4 points. This was perfect. Our cushions were sent out, shrink wrapped, and arrived in perfect condition. They fit like a glove and the client is extatic. We are too. I'm definitely keeping them on my Gold list of prefered vendors.
Great product!
Paula | September 4th, 2019
I am so glad that I chose this company. The replacement cushions fit perfectly and I have a "new" sofa and chair for the price of replacement foam. Couldn't be happier.
Great foam cushion replacement
Jackie Kever | September 4th, 2019
The foam cushion replacement was spot on. The foam was the exact density (after a suggestion from Foam Factory). It shipped quickly also.
First time purchase
Jodi | September 4th, 2019
This was my first time using this website. We bought a camper and needed to replace the cushions. I wasn't exactly sure how to order what we needed. This website made it so easy. We received our order and the cushions were perfect!
Custom cut foam
Noel A Veglahn | September 4th, 2019
Fast delivery and cutom cuts were right on. Excelent product and great comunications from company
Great Product! Great Service!
Fred Muller | September 4th, 2019
This is the first time I bought from Foam Factory and it won't be the last. Awesome customer service and fair prices, and I had the seat cushions custom cut for our dining room chaits. AAAAAA++++++
Bench Restoration
Fiona L | August 31st, 2019
I bought the High Quality Lux Foam in the 2" depth for a 100+ year old bench I was restoring. The springs on it went rather high, so I went with the firmest best foam I could find. I didn't trust myself to get the measurements perfect online, so I added a couple extra inches and trimmed accordingly with an electric carving knife (lol). Very pleased with how the bench turned out. It's very comfortable and the perfect density.
New Airstream seat cushions
Ronnie Dennis | August 29th, 2019
Ordered Lux-HD 5” foam to replace the soft foam in the factory seat cushions of my Airstream Travel trailer. Super fast shipping and great product.
Self Employed
Tanya Barnes | August 29th, 2019
We needed a new mattress for a bunk bed in a travel trailer. Finding a suitable mattress that was the right size and thick enough for comfort was very challenging. I came across Foam Factory and was a bit apprehensive to order online without seeing and touching the product, but the website was amazing with very clear photos and descriptions. This whole experience has been amazing! The foam mattress was everything we expected. The shipping was prompt and the package was well-sealed. We opened it right away and it was fully expanded within 24 hours. I highly recommend Foam Factory! Thanks!
Happy with my cushions
Barbara A Lippert | August 28th, 2019
My sofa is about 10 years old and the cushions had become too soft. I thought I needed a new sofa, but I took a chance and ordered replacement cushions- they arrived very quickly and my sofa feels new again!
Saved $1500
Therese | August 28th, 2019
Brought our 5 year old couch back to life and saved us from buying a new couch. I measured only from seam to seam and did not add anything extra. We like a firmer support and chose Lux High Quality. Make sure to get the Dacron wrap, it's worth and they do it right. Put the cushions back in the cover as soon as you can when they arrive. They will firm up and puff up a little bit since they are compressed when shipped. Great company!
Love my new cushions
Alena | August 28th, 2019
Needed to add firmness to my couch ordered cushions through Foam Factory and Love the fact that I can now sit on my couch and not sink in and kill my back. Received help from customer service rep Jeremy. Thank you :)
New life for my living room furniture
Jasen | August 28th, 2019
I had a nice set of leather furniture (couch, love seat, and chair) that I've had for close to 15 years. In that time, the cushions had lost their "springy-ness" and began to sag. After purchasing this replacement foam, my couch is like new again. The cushions are probably better than the original and are so comfortable. This probably bought me another 15 yrs with this classically styled furniture. Fantastic purchase!.
Parish Administrator
V. Smith | August 28th, 2019
We were very pleased with the product we ordered. It was easier to order to custom size than to buy a large roll and get stuck with alot of leftovers. Shipped and delivered in the time frame promised.
Great product that also saves you $$$.
Faraz A | August 28th, 2019
Great experience in upgrading my couch cushions. Team at Foam factory was fantastic in explaining different materials and with their help, I was able to order firm cushions for my couch to help my ailing mother easily get up from the couch at a fraction of the cost compared to buying a new couch.
Lucille Knapp | August 28th, 2019
smaller package, opens up really quickly and gets to full size very fast. Great product. thanks.
Very pleased
Linda Bucki | July 30th, 2019
I ordered replacement cushions for my sofa and couldn’t be more pleased. The descriptions of the foam were spot on. The cushions were nicely wrapped with batting and the sizing was as I requested. Price was great. I highly recommend them for all your foam needs.
Great products and customer service
Pamela Hoffman | July 21st, 2019
I highly recommend this company for all your foam/batting needs. The prices are very reasonable. The turn around time for shipping is excellent. AND, I love opening the packages and watching the foam “explode” as it expands! It is amazing to me too seed how compacted the products are when they arrive. Thank you for your excellent product and service.
Chairs like new
Denise | July 21st, 2019
Reasonable price, great stiff foam--what I was looking for. I would buy from them again.
couch like new
KBird | July 19th, 2019
Love love love. These were easy and fast to order. They fit great and have completely changed the feeling of our couch. Wish we had done this sooner.
Mark | July 18th, 2019
we have ordered custom foam to replace worn out RV cushions on two occasions. Easy ordering, fast delivery, perfect fit.
Awesome Serivce
DIY Gal | July 17th, 2019
I have recently competed my second custom cushion protject with high density foam. Great results with custom cut foam. Prompt delivery of exactly what I needed. Great service & prices!
Retired Guy
Bob Taylor | July 17th, 2019
Very pleased with my two new cushions for my RV sofa. Perfect fit and prompt delivery.
Foam Factory
Victor Badescu | July 17th, 2019
Very happy with the product, I will highly recommend this company for all the needs you may have. I am going to buy every time I need .
DIY success
Leonore | July 17th, 2019
I was apprehensive about replacing my foam cushions but after getting a $150 per cushion quote from my interior decorator I figured I’d try it myself. Got the firmest foam with dacron wrap (3 for a little over $100) and voila! Perfect.
Cushion purchaser
Katie W | July 12th, 2019
Very happy with the chair cushions I ordered. Great quality and reasonable pricing.
Very Satisfied
Awhitman | July 11th, 2019
Ordered new cushion inserts (Lux foam-High Quality with Dacron wrap) and was very happy with what I received. I was nervous about the measuring suggestion to round up AND add 1/2" but the inserts work perfectly, my covers fit snugly with no puckering or wrinkles. Would highly recommend.
Its like having a new couch
Beth | July 11th, 2019
We live on our outdoor sectional during the warmer months and we pretty much had sat out the cushions on it. I'm pretty sure the new foam inserts are even more comfy than the original pottery barn cushions.
Like a new couch
Joyce Luddy | July 10th, 2019
So glad we ordered new cushions, they came promptly, were a perfect cut and its like we have a whole new couch.
Deborah J Ireland | July 10th, 2019
Best price on a very good product. I will order from them again. Fast shipping.