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 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.

Write a Review

Excellent Product
Jacqueline Smerdel | February 15th, 2020
I ordered the high quality Lux Foam with dacron wrap for my couch and love-seat. The product was extremely high quality! The cushions have kept their firmness and shape and they have completely revived out couches! Additionally, the dacron wrap covered the whole cushion! Excellent quality! It feels like we got new furniture except it is even more comfortable than when we bought it! I would absolutely order from them again!
Well Made
Denise from Michigan | February 12th, 2020
Well built cushion - very high quality. Unfortunately, we measured the cushion size exact and should have deducted a couple of inches on all sizes to fit in the zippered cushion cover. That said, the cushion was of exceptional quality.
Replacement cushions for sofa sectional
April | February 12th, 2020
We thought we would have to buy a new sectional but these replacement cushions are great and we expect to get several more years out of this sectional which we love.
Kent McFarland | February 12th, 2020
I'm very happy with my foam purchase. I had a bit of trouble getting the right measurements to Foam Factory and they contacted me several times to be sure I had given them the right ones. Sure enough, once that was done the foam arrived, I put it in my cushions and now it's like having a new couch. The price was a little lower than another company I checked out.
Absolutely Amazing
Karen | February 12th, 2020
Was considering buying a new sectional but decided to order 2 cushions and see if that would help our sagging couch. They came within 2 weeks. It was like brand new cushions. We then measured and ordered the remaining foam for the rest of the sectional. $300 later and our sectional is like NEW. Saved at least $2000 and am totally satisfied.
couch cushion foam
mark richards | February 12th, 2020
WOW this is like a whole new couch, perfect firmness, thanks
Great product
Mike A. | February 12th, 2020
Foam was cut square to the sixteenth, and well wrapped in fiberfill. Shipping was quick and reasonably packaged. Will buy from again.
Everything was perfect
Brandon Skinner | February 12th, 2020
I ordered 3 custom cushions to replace the ones on my sectional. I had the sectional for 3 years and the cushions were worn out already, so we decided to just get bee cushions rather than a new sofa. They arrived quickly, fit perfectly (I used the sheet on how to measure that they provided), and are way better than the old ones.
Not Great!
Amy Nobles | February 12th, 2020
Ordered 3 huge cushions for sectional. 2 square cushions have firmness and are great. The L shape cushion sagged in right from the start. I opened them and went away on a trip for 4 days. Inserted them when I returned. L shaped cushion sagged in right from the start. I know it is not the couch because that portion of the sectional has barely been used since we purchased it. Only purchased the L to make sure all cushions were the same height. Pretty disappointed..
Satisfied repeat customer
John DeLaura | February 8th, 2020
This is the third time we have ordered replacement foam for furniture in our home. We are always very happy with the results. Perfect fit, fast shipping and great service.
order arrived quickly, measuring recommendations were very helpful
debbie gemmill | February 6th, 2020
order arrived quickly, measuring recommendations were very helpful
LS | February 5th, 2020
Purchased 3 lux foam seat cushions for my couch. Soft yet firm. Super fast shipping and the best price online. Would def reorder these visions again and would def recommend Foam Factory.
Custom Cut Lux Foam - High Quality
Kathy Nuckles | February 5th, 2020
Outstanding product. Foam is very high end and the cuts are all very clean and uniform. Highly recommend!
Angela Pardue | February 5th, 2020
This help our couch a lot. The cushions were getting flat and this gave them new life.
Perfect fit, good quality
Dustin | February 5th, 2020
My dog utterly destroyed one of two couch cushions and I wondered if I’d be able to match original quality. My Foam Factory replacement was a perfect fit, and the quality surpassed the original cushions. Luckily I had ordered two in case the new one didn’t match the original, and I’m glad I did! Overall great company, and I’ll most likely be ordering from them again, even if it’s simply to replace old worn out cushions.
replacement foam for couch cushions
pam grossman | February 2nd, 2020
i am so happy with my new couch cushions! the lux-hq foam is exactly as it is described and far surpasses the original foam my couch was made with - their pricing is very affordable and less expensive than other foam retailers online - with fast free delivery i’m a very satisfied customer!
Excellent Product & Delivery
Mindi Holtz | January 31st, 2020
I replaced the seat cushions in my RV and the new foam is perfect. May replace the back cushions now.
leather sofa cushions
Shawn perez | January 30th, 2020
I need to replace the down in a nice but older leather couch. I ordered these and it looks like new. So happy with my purchase, the timing and quality.
Excellent Results for Our Squishy Couch
Brian Rager | January 29th, 2020
I had been complaining for months about how much I sank down into our couch. I really hated sitting on it. But then I read about replacing the foam in the cushions and after some education I found my way to the website. Very clear and easy-to-follow instructions as to how to measure your existing cushions. Everything fit perfectly and I no longer sink in. I did spend a bit of time learning about density and firmness of foams, and this website had really good info about those factors. We chose the HD36 HQ foam and are super happy with the comfort. And finally, the price. I was pleasantly surprised at how reasonable the price was to get five pieces of foam and free shipping! And their order fulfillment was very quick (within a few days).
New couch cushions
Patricia Jones | January 29th, 2020
All I can say is THANK YOU! The new cushions solved all my problems. I was begining to believe I would have to buy new furniture, but now this furniture will be fine for awhile.
Great Company
Jane Shadle | January 29th, 2020
This is our second order. Our daughter was ready to toss the couch and since it was in good shape except for the cushions, I said let me order new and see how you feel. It is like a new couch and chair. I expected it to take weeks and we had them in 10 days even thou they were custom. This is a top notch company!
Cheryl | January 29th, 2020
I've purchased 4 different custom cushions from this company over the years for various projects including 2 bench cushions, 1 for a rv mattress, and 1 for an existing mattress as a topper. All have been fantastic!
john bacon | January 29th, 2020
foam cut to exact size and shipped much faster than expected. Will be buying again.
Best Quality/Service to our customers
CushNCovers | January 29th, 2020
I have used this company for years in my business. I order direct and have foam shipped to my customer's home while I make their covers. This saves me time and money. They tell me what I already know about the foam we select. It is very comfy and delivery is fast and reliable. I will continue to work with Foam Factory for my future orders. They even supplied the foam for our church pews we relayered. Highly recommend. Great customer service and friendly service to boot!
Wonderful Cushions
Sally | January 24th, 2020
I was thinking about buying a new sofa because the cushions had no support any longer.These cushions have given me a new sofa without the expense of buying one. The support is perfect and the fit is perfect.
Terrific product
Piper Mattson | January 24th, 2020
I ordered a wrapped piece of foam to recover a kitchen bench. It came timely, just as ordered, and seems to be a quality product. I'm glad I got the dacron wrap, adds all the more structure and comfort.
You saved my sofa!!
Fred | January 24th, 2020
From order start to installation, I found dealing with your company to be easy and pleasant. Your customer service rep was very helpful in choosing the right type of foam for my sofa cushions. The pricing was very good and shipping was quick. I would definitely recommend your company.
Glad I did it
Christopher A Sawyer | January 23rd, 2020
I was concerned about getting the dimensional measurements right, and that I would have difficulty stuffing the new foam in the covers. Neither weas a problem. And with a swift online order, I was able to completely transform two couches whose cushions had seen better days; all for less than $300. Gone are the divots and no longer supportive foam. In their place are firm, supportive seating areas that have give my two otherwise lightly worn couches a new lease on life.
Great service and product
Denise | January 22nd, 2020
I ordered a back cushion and seat cushion. Both were cut prefect and shipping was timely and very efficient
Perfect replacement cushions.
Mike | January 22nd, 2020
I ordered 7 replacement cushions to replace to dining table cushions on our new RV. The cushions that were supplied with the RV were so soft that you felt like you were sitting directly on the plywood. I measured the RV cushions and ordered the Lux foam replacements with the Dacron wrap. This was a custom size order and the cushions were delivered in less than a week. The cushions fit in the covers perfectly and the Dacron wrap helped to fill in the cushion covers. The best thing is that we can now sit at the dining table in comfort. I would highly recommend using Foam Factory and I will use them again in the future.
Don't know why I waited so long.
Becky | January 22nd, 2020
Perfect Cushions
Jeff | January 22nd, 2020
I love my couch and the old cushions had springs or something inside that folded up and made them horrible to sit on. These new cushions TOTALLY revived my old couch!!!
Excellent service and guidance, great results
Martha | January 9th, 2020
I ordered a custom cushion for a built-in dining area bench. The website descriptions of the foam selections available were very good and the measuring instructions helped me determine the exact size to order. It was a perfect fit and exactly what our seamstress asked us to provide. The option for a dacron wrap was a plus, as well as the price. I will be contacting the company for additional projects and have recommended the company to others.
Bill | January 8th, 2020
The quality of the foam is exceptional and the precision cut perfect. This is the second time I have used foam factory. This was a very large piece and it was cut perfectly. It was a quick delivery and packed extremely well. Don't hesitate this is a quality product at a great price.
Refreshed the sofa
Paul J | January 8th, 2020
The cushions fit perfectly and have refreshed the sofa to be better than new. The best was very little smell from the cushions and after I left them out for decompressing there was no smell at all.
Alicia Angeli | January 8th, 2020
I was bumming for a long time about my mushy, saggy couch cushions because I thought I would have to DIY replacements. I’m so glad I found this company.. very easy to order, high quality, and super affordable. I couldn’t believe the difference when I started using the new ones. Simply amazing what a difference it made! I couldn’t stop gushing about my new cushions!!
Excellent quality and very fast shipping
Michelle Kline | January 8th, 2020
I bought 4 cushions to replace some very worn out cushions in my couch. The cushions that came with my couch were low quality, and lost their support. These are perfect. The came packaged very well and very fast. This saved me from having to spend money I didn't have to replace a 3 year old couch. I should get 5 or more years out of it now.
Custom Cut Foam
Tina | January 6th, 2020
We ordered 6 custom cut foam cushions to replace the cushions on 2 couches. The order arrived promptly and the cushions are perfect! They are firm and really support your back. We are SO happy with our purchase and would definitely recommend this product. If we ever need replacement cushions again, we will be back! They also have wonderful customer service.
Custom cut foam
Janice | January 3rd, 2020
I ordered three pieces of foam to make cushions for a large window seat. I received the shipment promptly and the foam was cut to the perfect size. Now to get busy and get the the covers made!
Like new
TEC | January 3rd, 2020
Fit perfect, restored couch to like new feel.
Excellent service and quality
Arthur I Laursen | January 2nd, 2020
I replaced the foam in my Thomasville couch and love seat after 17 years. The original fabric was their highest quality and now they are back to like new again. I also replaced the cushions in our 6 dining room chairs. My wife absolutely loved the results!
Did the job
Gary | January 2nd, 2020
Very happy with the replacement foam for a couch cushion that I purchased. Will definitely use this product in the future if and when needed.
Perfect fit
Morse Taxon | January 2nd, 2020
We ordered a custom piece of foam to fill in the gap between our new queen mattress, and the waterbed frame into which we installed it. This worked perfectly, and was much easier than cutting the bed short.
Great couch cushion
Rebecca Storz | January 2nd, 2020
Sooo comfy, we absolutely love it!
Refurbishing a daybed
Gary | January 2nd, 2020
Made over a vintage daybed and wanted something comfortable to stretch out on. Ordered your best 8" foam and had it wrapped with dacron. It was delivered quickly (with good communtcation/updates) and was wrapped and bagged (saved the bag for transport). The measurements are spot on and the foam is super comfortable and supportive without being hard. Had shopped around locally but foambymail's prices could not be beat, not by a long shot. Extremely happy with this purchase and have recommended to friends. Would order from foambymail again in a heartbeat. All around, a great experience.
Great Save for Loveseat
Peggy Richter | December 30th, 2019
I too was a bit nervous about my measurements but cushion arrived and fit perfectly - thanks for extending life of vintage loveseat
Sofa & Chair like new again!
Sherri Sullivan | December 26th, 2019
My Mom's old sofa and chair was over 20+ years old but still looked new except for the cusions were crumbling apart like sawdust & very uncomfortable to sit. Replacing the cusions with your cusions has given us "like new" sofa and chair. Cusions are well made, very comfortable, & the fit was PERFECT! Foam by mail made the instructions for measuring easy and they were very prompt with my order. Thank You!!!
Great product
Patrick Wicichowski | December 26th, 2019
Great product and fast shipping .
Perfect solution for my couch
Kieran | December 26th, 2019
Was worried about my measurements but the replacement couch cushions came and fit in the slip covers perfectly. It's like I have a whole new couch. this was the perfect solution!!
Foam by mail? - of course!
Missy | December 26th, 2019
I contacted Foam by Mail with questions about ordering, and Amy got back to me quickly with measuring instructions. Of course, I was still nervous that my measurements would be off, and my new cushions would be just as bad as the old. I was so wrong! I ordered the cushions online ( L-shapes), followed the measuring instructions, and I couldn’t be happier with what arrived a couple of weeks later. My couch was saved! Thanks Foam by Mail!