Custom Couch Cushions

Build Your Couch Cushion

A couch rarely wears out all at once. The frame holds for decades, the fabric fades unevenly, and one evening a seat stays dished no matter how firmly you plump it. That dent is the foam core giving up — and it is why most couches hauled to the curb still had years of sitting left in them. What died was a replaceable layer.

Custom cut couch cushions, to your measurements — replacement foam cores for covers that are still sound, full seat-and-back sets when both layers are done — in 45–60D foam, every piece in one production run so the blocks match in loft and fabric lot. The frame’s model number never comes up: discontinued, hand-me-down and no-name couches are all the same to a tape measure.

Open the Customizer — Rectangle Preselected →

Seat blocks, T-cushion decks, back cushions — start with the shape below.

Enter each seat block’s width and depth, thickness, and back height — then pick your fabric tier and order the set in one run. Foam-only refills skip the customizer: measure the old core and order by cut size.

Need a different shape? Start from all 11 shapes →

Pricing — estimated starting at

*One couch seat block (24 × 24 × 5 in.): $45 make-base + 4.0 sq ft × rate ($30.79 per sq ft, 5" 50D foam + fabric). Three-seat couches are per-block multiples; back cushions price on their own area.

Refill lane: foam-only cores cut to your measurements price at foam rates — $6–7 per sq ft at 4–5 inch 50D — with no make-base, because we are not sewing a cover.

Common Couch Cushion Sizes

What a typical couch breaks down into (typical, always measure):

Match the original thickness when refilling — a thicker core changes seat height and how the back cushions lean against it.

Yours differs? That’s the point — we cut to your numbers.

How to Measure Couch Cushions

• Rebuilding? Measure the deck the pad sits on, seam to seam to the nearest quarter inch — the old pad has sagged into a shape of its own and will lie to you.
• Refilling? Measure the old core, or the cover’s interior with the closure open — the refill sizes to the cover, the rebuild sizes to the frame.
• T-cushion arms: sketch the notched outline with every dimension labeled — the full method is in how to measure a T-cushion sofa.
• Adjacent seat blocks should match within a quarter inch, or the joins show every time someone stands up.

Full walkthrough with photos: our measuring guide.

Indoor Fabric for the Couch You Actually Sit On

A refill leaves the old cover in place, so fabric is the decision on the rebuild and recover lanes. Three fabric tiers cover most projects: breathable cotton linen for covered spots, tech fabric for weather, premium velvet for indoor polish. Every fabric in the 119-option library is photographed in the configurator — zoom before you commit, because a navy that reads as slate on screen will not negotiate once it is sewn. The tier-by-tier comparison is in the covers guide.

Refill, Recover, or Rebuild: Reading a Worn-Out Couch

Before you order anything, find out which layer actually died. Open a cover and the couch tells you itself.

The refill lane — new cores, sound covers

If the fabric is still tight — seams intact, closure working, color you still like — and the seat stays dished, the foam is the only casualty. Replacement foam cores are cut to your measurements at foam rates, no make-base — the full cores-only spec is on our couch foam replacements page. Measure the old core flat: width, depth, and thickness at the center, never at the crushed front edge. Baggy old covers mislead — measure the cover’s interior seam to seam and subtract up to half an inch, so the fresh foam fills the cover snug without fighting the closure. Type the finished size — if you measured the cover interior, make that deduction yourself; we don’t deduct it twice.

The recover route — sound cores, tired fabric

Sometimes it runs the other way: the seat still sits firm, but the fabric is sun-faded on the window side, clawed at one arm, or torn at a single seam. New covers sewn to your cushion’s measured outline give the set another decade without touching the core — the full method is in our covers guide.

The full rebuild — when both layers are done

Pads from a few decades back are usually both at once: foam crumbled inside, fabric past recovering. Then you measure the deck itself and rebuild every block in one production run. Full replacement couch cushions price that whole-run rebuild piece by piece.

See all fabrics — pick by look, not budget — in the customizer.

Frequently asked questions

How much do replacement couch cushions cost?

Three lanes, three levels. Foam-only refills run $6–7 per sq ft at 4–5 inch 50D with no make-base — a 24 × 24 seat core lands in the double digits. Full replacement cushions run $45 make-base plus area, about $168 per 24 × 24 × 5 seat block, so a three-seat couch with backs lands in the mid hundreds. All of it a fraction of re-upholstery or a new couch.

How do I know if my couch needs new foam or new cushions?

Open a cover and look. Cover fabric tight, seams intact, seat dished — the foam died; order cores. Seat still firm, fabric faded or torn — recover the set. Foam crumbling and fabric past saving — rebuild both layers in one run. The dent test: a seat that stays dished after fluffing has compressed foam, and compressed foam does not rebound.

What foam density should replacement couch cushions be?

Match or upgrade from the original — factory couches often ship on light grades, which is why the seat died in five years. 45D serves a guest room; 50D is the floor for the couch the family actually lives on; 60D for heavy daily duty. Density buys years, and the front edge of the seat is where light foam fails first. For the grade-by-grade breakdown, see how to choose foam density.

Should the new foam core wear batting?

If the old core wore a batting jacket — a thin fiber wrap around the foam — replace it with the core. Batting rounds the square edge of cut foam, softens the sit, and takes the abrasion that would otherwise reach the cover seams. Match what came out of the cover: wrapped cores if the old jacket was doing its job, bare if the cover has its own lining.

Can I replace just one seat block on a couch?

You can, with two caveats. The new block will sit prouder than its flattened neighbors for the first months, and fabric cut from a different lot can read a half-tone off the old covers in daylight. If more than one block is dead, ordering the set in one production run avoids both.

What’s the difference between custom and replacement couch cushions?

Nothing in the process, everything in the starting point. Custom starts from your frame’s deck measurements for a new build; replacement starts from the old cushion’s outline to rebuild what was there. Either way the cut is to your numbers — which is why both words land on pages quoting the same formula.

How long does a couch cushion set take?

Your order starts at the cutting table: production is 4–7 business days, with rush production at 3–5 business days for a surcharge. Delivery is 3–6 weeks door to door. Typical US custom shops quote 3–6 weeks for the same build.

Do your cushions come with piping or welt cord?

Not as a standing option. Our sewing standard is clean, cord-free knife-edge seams — no decorative cord on any shape, any fabric. The flat profile wears evenly at the corners, cleans flat, and never traps debris along a raised seam.

Can I send my own fabric?

Not at this time — we sew only from our own library, so customer-supplied fabric isn’t a service we can take on. What closes the gap: the 119 fabrics in the configurator, each photographed close enough to read the weave before you commit, plus free swatches on request — email [email protected] with the fabrics you’re considering.

Where are your cushions made?

In our own overseas factory — cut and sewn to your measurements, shipped factory-direct to your door. What decides how long a couch cushion lasts isn’t the country on the label; it’s foam density (we build on 50–65D foam), the fabric family (the weave you pick for the room it lives in), and seam construction — and we publish the numbers for all three. Factory-direct is why the same spec costs 40–60% less than a local shop: no middleman, no warehouse, no storefront. If made-in-USA is a hard requirement, a local upholsterer is the right call — budget 2–3x for US labor hours. Every order is made in 4–7 days, arrives in 3–6 weeks, and is backed by our free remake guarantee.

Is a Couch Cushion Right for You?

• Know which lane you are in before the customizer. Cores still firm but fabric sun-faded is a re-cover conversation, not a cushion order; cores flattened under sound fabric is the foam-only refill lane at foam rates with no make-base — ordering the full sewn set when only foam died is paying for work you will throw away.
• Measure the finished size, and deduct once. If you measure the cover interior, make the quarter-inch deduction yourself before typing the numbers — we do not deduct it twice, and a double-deducted cushion arrives visibly loose in its own cover.
• Unsure about color? Email the factory before you order. Screens shift color, and living light shifts it again — send a photo of where the cushion will live and we will tell you honestly how each fabric reads in that spot. The two-minute email is cheaper than a wrong-color guess.
• Custom-cut means non-returnable. Custom-cut means non-returnable. A cushion cut to your numbers fits exactly one frame on earth — tolerances are published in writing (±½″, ±¾″ over 36″), and anything outside them against your confirmed numbers is remade free, whenever the error is found.

Made by the factory that ships them

• Outdoor cushion factory for 10+ years — we cut, fill, and sew every order ourselves.
• Every dimension you send is re-checked before a single yard of fabric is cut.
• Made-to-order means any fabric, any piece, no minimum.
• If we cut it wrong — outside the ±½″ tolerance (±¾″ over 36″), wrong fabric, wrong build — remade free.

Custom couch cushions from $168 per seat block — foam-only refills from $6–7 per sq ft.

Build My Couch Cushion →

Block-by-block sofa build? See the sofa cushion guide →