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
Cliff - Maynard, MA | March 18th, 2026
I was somewhat hesitant ordering two Arched-L shape cushions because of the unusual shape. They ended up fitting perfectly after following the measuring instructions provided ! I had been prepared to cut them if needed but was very happy. Also, the two rectangular shapes fit perfectly. I’d originally been planning to do it all as a DIY project and realized it simply wasn’t worth it considering I’d have to buy a knife, adhesive spray, Dacron and the effort & driving around to get materials.
Jason | March 18th, 2026
I replaced two of the cushions on my outdoor furniture set and I like these more than the originals! Followed the measuring instructions and they fit perfectly. Shipping was also fast and arrived on time.
C. Sherk | March 18th, 2026
After searching for a durable solution to revive our living room couch, we decided on the Lux High Quality foam, and it has been a total game-changer. Since we use our sofa daily and are both over 200 pounds, we needed a material that could actually withstand heavy, consistent use. It has been over two months now, and I’m impressed that the foam remains just as firm as the day we unboxed it. This is a massive improvement over five years ago when we actually paid to have the couches professionally redone, only to have those cushions go flat almost immediately. The ordering process was seamless, the shipping was surprisingly fast, and the DIY steps were very easy to follow. We are beyond satisfied with this purchase and will definitely be using this foam for any projects going forward.
Jeffrey Shilt | March 12th, 2026
Working on my very first re-upholstery project, slowly, bit by bit. The 3" luxe foam is very nice feel to thickness and density, and great price. The dacron covering certainly worth the extra and was nicely wrapped/stapled around the cushion. Although I un-stapled it to use separately as I needed to cut the foam to the shape of the seat. The foam also cuts nicely with just a kitchen-type electric knife.
Very happy with the purchase and can't wait to finish my project and sit down to enjoy it :)
Shane | March 11th, 2026
Just what I was looking for, that you for fulfilling my needs.
Maria | March 11th, 2026
I am so pleased with my purchase. The cushions of my giant sectional are like new again! Website measuring instructions were clear and customer service guidance was prompt, thorough, helpful and reassuring...especially for a DIY project. Highly recommend your product and service!
Ben B. | March 10th, 2026
I followed the measuring instructions and the results were perfect. The Dacron wrap was extremely well done. Great workmanship., highly impressed.
Josh | March 10th, 2026
I purchased new foam for a 7-8 year old West Elm Andes sofa that had become very uncomfortable, with cushions that lost any semblance of support. I ordered HD36 high quality foam with dacron wrap and couldn't be happier. It is absolute perfection. When I removed the old cushion and looked at the new one, I was really worried it wouldn't fit, but they're right, don't order a smaller size, the dacron makes the cushion look a lot larger, but you can get it in the cover just the same, and the result is the most satisfyingly plump fit and supportive feel you can imagine.
Melisa | March 9th, 2026
Purchased new foam for my recliner seat and it's incredibly comfortable. Great way to stretch your dollar!
Bob Driscoll | March 9th, 2026
Purchased 2 custom 6" inch cushions to replace very worn out originals. Love the product, they are easy to install, make the sofa the look like new and I love the firmness. No more sinking into the seats.
Sallie | March 9th, 2026
This is my second purchase from the Foam Factory. Last year I ordered three replacement cushions for my outdoor furniture. This year I purchased the remaining needed. Customer Service was great, making sure I was measuring correctly. The order was produced and shipped quickly. And, the quality is spot on. Foam Factory is my ‘go-to’ for all my foam needs.
Benjamin | March 9th, 2026
So happy we found this site. Got new foam for our dinette cushions in our RV. The guideline to follow with measure was spot on. At first I was afraid they wouldn’t fit but everything went smooth. Perfect price for a quality product.
Cynthia | March 9th, 2026
We are so happy with the new cushion inserts. What a difference in comfort! Customer service was very helpful!
SK | March 5th, 2026
I'm very happy with my new cushion replacement, it feels like a brand new couch! Everyone loves the firmness and it was so easy to order with no questions. Thank you again.
Denine | February 26th, 2026
Foam was just as ordered and priced well. Delivered quickly and am very pleased. will use this company again.
Steve | February 26th, 2026
I bought a cheap couch 3 years ago and the cushions started bunching up on my pretty quickly. I found these guys, measured out my cushions and what they delivered was the perfect, reasonably priced solution. Huge thumbs up.
Mary Z | February 26th, 2026
Worked out great. Definitely saved me money. Quality materials !
Jim | February 26th, 2026
Appreciated the guidance on the the type of foam to order. Product received and works well
Tina | February 18th, 2026
I ordered replacement cushions for a used leather sofa I bought from a thrift shop. The sofa was in excellent shape but needed firmer cushions. I called customer service twice and found them to be very helpful. The online tutorial was also good too to help us decide what type of foam we wanted. Each cushion had a pillow top cushion which we replaced as well, so we ordered 6 pieces of foam in total . We saved a lot of money in the long run. We are very happy customers.
Thomas Forrester | February 18th, 2026
The price that I ordered was very good and the time it took to get here I understand for some of it takes a little longer than others, but they did a very nice job on what I wanted and it’s cut to exactly how I wanted it. Thank you.
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 !
