Custom Sunbrella Cushions
Custom Sunbrella cushions are made-to-order outdoor cushions cut to your exact measurements in solution-dyed acrylic — the fade-resistant fabric class Sunbrella is famous for. CushionMill sews any size, any shape, in 38 outdoor fabrics from our own factory: 4–7 business day builds, from $89, with a free remake if our cut misses your numbers. Every fabric one price. The full fabric comparison, care guides and transparent pricing are below — or browse the parent custom outdoor cushions hub.
Cut and sewn by the factory that ships them — no middlemen.
Performance outdoor fabrics that stand up to sun and rain.
Every dimension re-checked before cutting. Outside tolerance, remade free.
If we cut it wrong, we remake it — no arguments.
Custom Deep Seat Cushions
- Cut to your exact measurements — any deep-seating frame, any brand.
- 119 performance fabrics at one price — full-sun and quick-dry outdoor lines included.
- One order, one dye lot — every piece in the run ships color-matched.
- Factory-direct from $172 — instant quote in the customizer below.
- ±½″ tolerance, re-checked before cutting — remade free if we cut it wrong.
Custom Outdoor Seat Cushions
- Cut to your exact measurements — wicker, wrought iron, wood and lawn frames, any seat deck.
- 119 performance fabrics at one price — full-sun and quick-dry outdoor lines included.
- One order, one dye lot — every piece in the run ships color-matched.
- Factory-direct from $113 — instant quote in the customizer below.
- ±½″ tolerance, re-checked before cutting — remade free if we cut it wrong.
Replacement Patio Cushions
- Replacement patio cushions cut to your measurements — one seat pad or the full set, no minimum.
- 119 fabrics at one price — solution-dyed acrylic, olefin blends and covered-porch weaves in one order.
- Quick-dry reticulated foam for uncovered sets — drains in seconds, dries in hours.
- Measured shelves for Hampton Bay (24 series) and Martha Stewart (7 series) patio lines.
- Cut to a ±½" tolerance — outside it, remade free, any time. From USD 94 a seat.
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
What “Sunbrella cushions” actually means
Sunbrella is a fabric brand — the Glen Raven mill in North Carolina — not a cushion maker. The name became shorthand for the fabric class itself: solution-dyed acrylic, where the color pigment is locked into the fiber before it is extruded, so the color is the fiber all the way through. That is why covers in this class fade on a schedule of years, not seasons, while a printed polyester cover starts going chalky by the second summer.
We are a cushion factory, not a fabric brand: our 119-fabric library carries solution-dyed acrylic outdoor lines alongside olefin blends and coated canvases, and the specific pattern names are visible in the fabric menu of the order flow. What we cut for you is measured to your pieces — the fabric class is the part you already knew to ask for.
Three fabric routes for cushions that live in the sun
- Solution-dyed acrylic (the Sunbrella class) — color is engineered into the fiber; fade measured in years. The pick for full-day sun, south- or west-facing exposure, and dark colors you want to keep dark.
- Olefin blends — very good UV stability for the price, slightly plainer hand. The budget-conscious route for full-sun builds.
- Coated canvas — surface print and coating; beads water best at first, fades first. Covered porches and seasonal use.
The full head-to-head — warranty terms, mildew behavior, cleaning — is in our Sunbrella vs regular outdoor fabric comparison, and the maintenance routine that stretches any of them is in the Sunbrella fabric care guide.
Made to your measurements, not to a size chart
Every order is cut after you measure — width, depth and thickness at the seam, three numbers per cushion. Any shape we cut is on the menu: square and rectangle seats, deep seating, benches, chaise pads, dining chairs, wicker frames, L-shapes, bowed and rounded pieces. Foam runs 35D through 65D (our standard recommendation is 60D for seats, 50D for backs), and covers close with a zippered closure so they remove for washing.
One caveat specific to sun-faded sets: old covers shrink slightly as they bake, so measure the seat deck, not the old pad, when the two disagree — the deck is the truth the frame still holds.
Transparent pricing, every fabric one price
Custom pieces start at $89 (a 16 × 16 × 2 in. pad) and scale with size and density. The formula is public: a $45 make-base per piece plus area at per-square-foot rates — foam by density and thickness, fabric flat at $7.43 per square foot, every one of the 119 fabrics at the same rate. A typical dining chair pad (18 × 18 × 3 in.) lands at $105; a deep-seat pad (24 × 24 × 5 in.) at $168. Shipping is free over $158, flat $29 below it. The configurator figures your exact numbers live, and the quote is settled before anything is cut.
How ordering works
You measure, pick fabric, and confirm the quote — we cut, fill and sew. Builds run 4–7 business days (rush service 3–5), then shipping to your door; plan on 3–6 weeks door to door. Nothing is stocked and nothing is brokered: any fabric, any piece, one cushion or forty, made in the same workshop that has been sewing cushions for 10+ years. Before any fabric is unrolled, the measurements you sent are re-verified against the piece count. And if our cut lands outside ±½ in. (±¾ in. beyond 36 in.), or the fabric or build is wrong — it is remade free of charge.
Open the customizer with outdoor fabrics preselected → Or start from the flagship Sunbrella replacement cushions — custom cut to your measurements, or browse the full line in the custom outdoor cushions hub.
Care that keeps the color you chose
Solution-dyed acrylic does not bleed: mild soap, warm water and a soft brush, then rinse and air-dry. Never machine-wash or machine-dry — heat and agitation are what actually ruin the fabric. The full routine, including stubborn mildew spots, is in the Sunbrella care guide; choosing the colors that hold their depth longest is charted in Sunbrella colors.
Frequently asked questions
On a fully exposed patio, yes — solution-dyed acrylic is the class that holds color for years. On a covered porch that gets an hour of sun, the olefin and coated lines close most of the gap at a friendlier rate.
We are an independent cushion factory, not a Glen Raven dealer. Our 119-fabric library carries the solution-dyed acrylic class Sunbrella is famous for; the specific pattern names are shown in the fabric menu of the order flow. You pick the exact cloth; we cut to your measurements.
Fade in this class is measured in years of full sun, not seasons — the pigment is inside the fiber rather than printed on it, so UV has to work through the whole strand.
Usually close, sometimes exactly — swatch-scale color families (navy, canvas, fern, terracotta) run across makers. Order one seat pad first if you want to judge the cloth against your set before committing to the full run.
From $89 for a small pad; typical pieces run $105–$198 depending on size and foam density. Every fabric is one price, and the final quote is confirmed before anything is cut.
Crafted in 4–7 business days, rush 3–5, then shipping to your door — plan on 3–6 weeks door to door.
CushionMill is an independent cushion workshop, not affiliated with Glen Raven or the Sunbrella brand. The name is used to identify the fabric class people are shopping for; the specific pattern lines available for your order are listed in the fabric menu at checkout.