Custom Round Cushions — Any Diameter, Any Thickness
Round seat cushions for bar stools, bistro chairs, ottomans, and round benches — cut to the exact diameter and thickness you measure. Factory round pads are usually thin fill under loose circles, and they shrink into wobbles of spare fabric within a season or two; universal replacements come in whole-inch sizes only. Send two numbers and a photo, and we cut a high-density circle that fits the seat deck exactly.
Start with your shape
Not sure? Pick the closest — every measurement is confirmed before we cut.
Don't see your shape? We make any shape.
Straight edges? A top photo + the edge numbers is all we need. Curved? Trace it on paper next to a tape measure and email us a photo.
Enter your measurements
Measure the old cushion flat, edge to edge — never the frame.
Choose your fabric
Five families, 119 cuts, one flat rate — pick by look and feel. Click a family to see its swatches below, or its ⓘ for what the fabric is and where it works best.
All covers cut to your exact dimensions — no stock sizes, zippered covers that remove for washing.
Review & order
Calculated live from your measurements — every line, no surprises.
Free shipping over $158 · $29 flat below
Estimates only — we re-verify every dimension before cutting and will contact you if anything looks off. Prefer email? Email me this quote
Odd shape or tricky frame? Upload a photo of your furniture or old cushion — one overall shot, plus a top and side view of the old cushion if you can.
JPG, PNG or WebP · up to 10 MB each · max 3
The workshop that cuts it is the one that ships it
Every fabric on the list, open in the configurator
Any fraction, any thickness — not whole-inch shelf sizes
Miss on our side and the remake is free
Why Round Cushions Fail First
A round cushion fails differently from a square one. As foam ages it shrinks, and on a circle the shrink shows immediately: the pad starts swimming in its own cover, spins when you sit, and the edge you see from across the room goes limp. Factory rounds on stools and bistro chairs are typically the thinnest fill in the house, because they were sized for looks at purchase, not for the ten years of breakfasts that follow.
Diameter tolerance is brutal on circles. A 15 1/4-inch stool deck with a 15-inch pad shows a bare ring of seat all the way around; with a 16-inch pad the fabric puckers into waves. There is no “close enough” on a circle — the eye finds the gap instantly. Yet the shelf offers nothing but whole inches, which is why so many stool pads spend their lives visibly wrong.
The good news: a circle is the easiest shape to order well. Two numbers — diameter and thickness — describe the whole piece, and a second diameter reading at a different angle confirms the seat is truly round. Custom is cheaper than you expect here, too: a circle uses less fabric than the square around it, and our customizer prices the true area.
Why order from a mill instead
Every cushion is cut after you order, from your measurements: high-density foam in the density you pick, in any of 119 fabrics, sewn to a quarter-inch tolerance. If a piece lands outside that tolerance, we remake it free. The customizer above prices your exact diameter in real time — no quote wait, no email ping-pong before you see a number.
| Big-box universal pad | Cushion Mill custom cut | |
|---|---|---|
| Fit | A ring of bare seat shows | Your diameter, ±½″ |
| Foam | Fixed low-density fill | 35D / 50D / 60D, your choice |
| Fabric | 3–5 colorways | 119 fabrics, one flat rate |
| Diameter | Whole-inch sizes only | Any fraction, cut to the number |
| When it wears | Buy a new set, same wobble | Re-cut the same specs in minutes |
Round Cushion Diameters — What We Typically See
| Piece | Typical range | Notes |
|---|---|---|
| Bar and counter stool pad | 13–16 in. dia. × 2–3 in. T | 15 in. is the most common deck we cut for |
| Bistro / café chair pad | 17–19 in. dia. × 2–3 in. T | French bistro sets and round-seat chairs |
| Ottoman and footstool pad | 18–22 in. dia. × 3–4 in. T | Round ottomans get sat on more than feet expect |
| Round bench / large circle | 30–48 in. dia. × 3–6 in. T | Round benches, papasan bowls, egg-chair bases |
Pricing — estimated starting at
| Piece | Example size (dia. × T) | Foam | Estimated price* |
|---|---|---|---|
| Bar stool pad | 15 × 2 in. | 50D | $75 |
| Bistro chair pad | 17 × 2.5 in. | 50D | $86 |
| Ottoman pad | 20 × 3 in. | 50D | $104 |
| Round bench pad | 36 × 3 in. | 50D | $223 |
*Per piece, calculated live in the customizer with the exact numbers you enter: a $45 cutting charge per piece, foam priced by density and thickness, and fabric at one flat $7.43/sq ft across all 119 options. A circle is priced on its true area — never on the square around it. These anchors are honest arithmetic, not teaser rates.
Doing the whole counter? Stool pads, a matching bench pad, and floor pillows can ship in one order, and the customizer prices each piece as you add it — no bundle guesswork.
Foam & Thickness for Round Duty
| Foam | Best for | Typical thickness |
|---|---|---|
| 35D | Occasional stools, decorative ottomans | 2–3 in. |
| 50D | Daily bar stools and dining rounds | 2–3 in. |
| 60D | Round benches and papasan bases you sink into | 4–6 in. |
Circles concentrate weight dead center — a round pad is effectively a small mattress for whoever sits on it. For a stool you perch on, 50D at two inches is honest. For a round bench or papasan you actually settle into, 60D with real thickness is what keeps the center from packing out first. Thicker circles also hold their silhouette, which matters when the pad is the seat’s whole look.
How to Measure a Round Cushion
For rounds, the seat deck is usually the better master than the old pad — tired foam has shrunk and lies about the size. Measure the deck, not the wobble.
- Diameter — straight across the widest point with the tape passing over the center. Read it again at a different angle: a true circle measures the same every time.
- Thickness — bottom to top with the foam resting naturally, not squeezed.
If your two diameter readings differ, the seat isn’t round — it’s an oval, and the fix is an oval cushion with two numbers (long axis, short axis), which we cut as an oval, not as a compromise circle. One photo of the tape laid across the seat settles everything. We cut to ±½″ and remake free if a piece misses it.
Fabrics for Round Seats
Round pads live where life happens — stools at the breakfast counter, ottomans that double as footrests and, on movie night, as seats. Choose fabric for the abuse:
- Tech Fabric — waterproof, wipe-clean; the honest answer for breakfast-counter stools.
- Cotton Linen — soft and natural for bistro chairs in dry, mild rooms.
- Pet-friendly weaves — claws find round pads easy targets; these weaves don’t care.
- Chenille & velvet — for ottomans whose real job is looking good.
All 119 options price at the same flat rate — and a circle uses less fabric than a square of the same width, so the customizer’s price reflects the true shape automatically. Pick by duty, not by budget tier.
Round Pieces We Cut Every Week
- Bar and counter stool pads — 13 to 16 inch circles are daily work
- Bistro and café chair pads for French-style round seats
- Round ottoman and footstool pads, thick or thin
- Round bench pads and large circles for table bases
- Egg-chair and papasan base circles cut to the bowl
Half-rounds and D-shapes — a circle with one flat back edge — are selectable in the customizer. For a circle with a notch, a wedge out, or an umbrella-hole donut, send a paper template with your order and we cut to the line.
Before You Order — Worth Reading
- How to measure a round cushion — diameter is not enough: the full discipline, illustrated
- How to measure an oval cushion — for the seats that read two different diameters
- D-shaped cushions — the flat-back round spec, explained
Frequently asked questions
How do I measure a round cushion for replacement?
Measure the diameter straight across the widest point with the tape over the center, then read it again at a different angle to confirm the seat is truly round. Thickness is bottom to top with the foam at rest. If the two readings differ, it’s an oval — send both axes and we cut an oval. One photo of the tape across the seat helps. We cut to ±½″ and remake free if a piece misses it.
My stool measures a fraction like 15 3/8 inches. Should I order 15 or 16?
Enter 15 3/8. A 15-inch pad shows a bare ring of deck all the way around; a 16 puckers into waves. Custom exists precisely to cut the fraction — the ±½″ tolerance is measured against your number.
What’s the difference between a round and an oval cushion order?
One diameter versus two. A round is a single number across every angle; an oval needs a long axis and a short axis. If your diameter readings at different angles differ by more than half an inch, order the oval with both numbers rather than splitting the difference.
What thickness should a round stool cushion be?
2–3 inches at 50D covers nearly every stool duty. Save 60D and 4–6 inch thickness for rounds you sink into — benches, papasan bases, deep ottomans — where the center of the pad carries real weight.
Can I order just a round cover, not the foam?
Yes — we sew replacement covers to your diameter and thickness in the same 119 fabrics, with a zipper where the original had one. If the old cover still exists, mail it and we pattern from it directly. Press the old pad hard first: if you feel the deck through it, the foam is done too.
Do round cushions cost more than square ones?
Usually less. A circle uses less fabric than a square of the same width, and our customizer prices the true area of the shape — you’re never paying square prices for a round piece.
How do I order a set of matching stool pads?
Enter the piece once and repeat it for each stool in the customizer — each prices as you add it, identical pieces cost identically, and one order ships together with fabric from the same bolt.
How long do custom round cushions take?
Standard builds leave the workshop in 4–7 days, rush builds in 3–5, with shipping typically 3–6 weeks. Your order confirmation states the exact dates for your build slot.
Made and Shipped by the Same Hands
- Cut in our own workshop — factory direct, no middleman
- Standard build 4–7 days, rush 3–5 days
- Shipping typically 3–6 weeks, tracked
- ±½″ tolerance or we remake it free
Custom round cushions from $75 — two numbers per piece in the customizer to a live price. Enter your diameter and thickness, pick density and fabric, and the number is on screen before you commit.
Ready when you are. Measure the seat deck tonight, enter the diameter, and the stools are a weekend job from done.