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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What a great experience working with the Foam Factory
Ted Sheldon | June 19th, 2019
What a great experience working with the service people at Foam Factory, especially Amanda. Despite the fact that I had one tiny order I was treated as it was a million dollar sale. I received samples, then wanted to hold my order because I was going to be out of town for a week, and delivery was UPS, asked if I could place order on returned. I called them and they had my info, placed the order, and received within a week. My custom cut piece of foam was perfect, great experience, would do business with them again.
No more fabric store foam!
Susan | June 19th, 2019
Salesperson have me some excellent advice on the best foam to select to redo antique dining room chairs. This is the best place to order quality foam.
Great Product
Kelly | June 19th, 2019
Ordered two custom cut foam pieces for dog bed replacement cushions. Foam pieces were cut to exact ordered size and shipped quickly. Very happy with the product.
Great quality!
Kate | June 5th, 2019
Foam by Mail is wonderful for custom dog beds! I’ve ordered foam to fit her crate and two ‘soft box’ beds and have always been satisfied. Prompt service, high quality, and exact to ordered size.
Great product
Drew | May 29th, 2019
I couldn't be more pleased with my experience with The Foam Factory. My sofa's upholstery covers are in fine shape, but the cushions were totally shot. I brought the sofa back to life, better than new, with the Lux foam with Dacron wrap. The sofa now feels like a comfy, firm mattress. I wouldn't take a new sofa now if it was offered to me.
Bill | May 20th, 2019
I had ordered cushions for a sofa. I was unsure about doing this myself so I initially ordered just the seat cushion. My wife was so happy she anted the back cushions replaced. The back cusions were now a usual shape and following the instructions on the web site I ordered the back cushions which turned out great. Shipping quick. Very happy with two purchases.
Just like new
Carla Weinkauf | May 19th, 2019
I had custom cut cushions made for my love seat and sofa. It made them feel and look like new. I'll be able to keep this furniture for at least another decade for 10% of the price of new furniture, I am very happy!
Thank You!
Andrew | May 17th, 2019
Great Product! Our couch is like new again. We recently had a family gathering and everyone complimented on how comfortable our couch was! Thanks for a great product, at a great price and excellent customer service!
Just like new!
Gina | May 16th, 2019
I ordered new cushion inserts for our sofa and two easy chairs. I followed the instructions for measuring, and picked high quality foam since this furniture gets a lot of use. I'm really happy with how it turned out. We are comfortable again and saved a lot of money by not having to buy all new furniture . Highly recommend this company!
What a difference!
Bobby C | May 16th, 2019
We replaced the stock seat cushions on our RV with two new Lux cushions from the Foam Factory. What a difference in comfort! Plus assistance in selecting the right product and free shipping.
Senior Environmental Pleasure Seeker
P. J. | May 15th, 2019
...needed foam insert.cushion replacements...very fortunate to purchase from foam by mail...quick delivery...excellent guests will be so comfortable, they may never leave...any foam needs in the future will be directed, quite happily with foam by mail...thanks Carlo!
Great Quality
Lori Norman | May 15th, 2019
My order was processed and shipped quickly and arrived in great condition. I unwrapped the foam and it was perfectly shaped in just a few hours. I was pleased also with the website and the information provided on each type of foam so I knew which best fit my needs. Great Job Foam Factory! I will be ordering from you in the future.
Cynthia | May 15th, 2019
I have ordered several different cushions, and always VERY pleased. Just replaced some older chair cushions and they are perfect. The instructions for ordering have always worked!! So glad I found this company!!
Home owner
Barbara Tetlow | May 15th, 2019
Just exactly the density I needed for a window cushion. Arrived right away. The window seat looks great now.
Custom cut cushions
Vicky | May 13th, 2019
I have ordered several custom cut cushions that were done with perfection and quick arrival. I would highly recommend this company.
Great product
Alex | May 9th, 2019
I created great cushions for my vintage trailer and now this is a high end sleeping bed with class and style. The foam came quickly and EXACTLY as described. Thank You Foam Factory
Perfect Fit
Linn G Hastings | May 9th, 2019
I ordered new cushions for an older outdoor chair set. After looking for 2 years , no new cushion would fit the size I needed, decided I needed to try replacing the foam and try to do it myself. The order process was so easy, the foam quality was more than I expected, the cushions were here in 3 days, the cut was perfect. Do not hesitate to purchase, wonderful service and product.
SteveN | May 8th, 2019
I had a Raymour and Flanagan sofa with cushions that failed to maintain any support. They were replaced twice under warranty. Then they are no longer available. So I found foam by mail and got three great firm cushions. Excellent.