Custom Outdoor Sectional Cushions, Made to Your Measurements
Factory-direct, cut block by block — seats, corners, chaise ends, backs.
A sectional is not one cushion with a part number — it is a family of blocks: straight seats, a corner wedge with two different depths, a chaise end, fiber backs, maybe an ottoman. The two classic mistakes are ordering by seat count ("five-seat sectional, five cushions" — wrong, the corner and chaise are not seats) and ordering matched sets where the original ran asymmetric blocks.
We cut outdoor sectional cushions block by block from your measurements — T-cushion arms, notched chaise ends, hinged sleeper sections — in 45–60D foam for daily family use, with weatherproof fabric tiers for patio sets and the full indoor library for living-room frames. Discontinued is our home turf: a workshop that cuts to dimensions instead of model numbers can rebuild every block you have.
Build Your Sectional Cushion
Build your sectional cushion — start with the shape below.
Enter each block’s outline — T-cushion arms take the notched outline — then pick your fabric tier and order the family in one run.
Open the Customizer — T-Cushion Preselected →Need a different shape? Start from all 11 shapes →
Pricing — estimated starting at
| Fabric tier | Estimated price* |
|---|---|
| Cotton Linen | $111 |
| Tech Fabric | $116 |
| Premium Velvet | $121 |
*One seat block (24 × 25 × 5 in.): $39 make-base + 4.2 sq ft × rate ($17.38/$18.49/$19.62 per sq ft, 5" 50D foam + fabric). The set price is driven by the number of blocks and their square footage — corner wedges, chaise ends and backs each price on their own area.
For comparison: U.S. custom-configurator specialists’ 2026 listings run made-to-order cushions well above formula price once configured — and most only reveal that number after a quote request. We publish the formula above so you can check the math before you order.
Popular Sectional Sizes We Cut
The blocks a typical L-shaped sectional breaks down into (typical, always measure):
| Piece | Typical size | Notes |
|---|---|---|
| Seat blocks | 22–25 W × 24–27 D × 4–5" | Count them: some makers join two seats into one long block — common stock squares: 24 × 24, 25 × 25, 26 × 26, 28 × 28 |
| Corner block | ~27 × 27 wedge, two depths | Neither seat nor chaise; most often mis-ordered as "a square cushion" |
| Chaise end | One long rectangle or an L-shaped piece | L-shapes are cut as one piece, not two |
| Back cushions | Match seat W × 18–26 H | Fiber-filled, counted separately from the foam seats |
| Hinged pieces | Fold on a hinge line | The fold position is a dimension, not a suggestion |
Yours differs? That’s the point — we cut to your numbers.
How to Measure a Sectional Cushion
- Count and name every block first — seats, corner, chaise, backs, ottoman — as a floor plan; then measure the blocks themselves, not the impressions they leave on the frame.
- Width and depth seam to seam to the nearest quarter inch; adjacent blocks must match or the joins show. Measure as a family: three blocks reading 24, 24.25 and 24 were cut 24 and stretched — order three at 24.
- Corner blocks get both depths — front edge and side edge; many wedges are not square, and a 38 × 38 guess on a 36 × 40 reality leaves a gap at the elbow.
- T-cushion arms and chaise notches get sketched: outline on paper, dimensions labeled. Hinged pieces: measure the hinge line.
Full walkthrough with photos: our measuring guide.
Build details — sewing style and fastening options confirmed with your dimensions before cutting.
Covers, Inserts, or Full Cushions
Sectionals are the category where the three replacement paths diverge: cover-only when the fabric died but the cores rebound; insert-only when the cores flattened but the covers live; full cushions when both died. Our foam runs 45–60D for daily family use (50D and 60D grades) — the corner and chaise blocks carry more concentrated lounging than straight seats, so they are the wrong blocks to economize on. Fabric tiers price per square foot like everything else we cut; the T-cushion measuring method is laid out in how to measure a T-cushion sofa.
Seven of the 119 fabrics in the swatch library — free samples ship with every quote.
Frequently asked questions
Can I order standard sectional cushion sizes?
Standard sizes too — in 3 clicks: seat blocks cluster around 24 × 24 to 24 × 26 at 4–5 inches — stock squares like 24 × 24 and 24 × 26. Type any block’s numbers into the customizer for the same instant factory-direct quote — corner wedges and chaise ends are the blocks that actually need measuring.
How do you replace cushions on a sectional?
Block by block: count and name every piece (seats, corner wedge, chaise, backs, ottoman), measure each to the nearest quarter inch as a family, then order covers, inserts or full cushions per block — a sectional is a set of shapes, not one part number.
Can you buy replacement cushions for a sectional that is discontinued?
Yes — not from the brand, but from measured replacement: any workshop that cuts to dimensions instead of model numbers can rebuild every block, which is exactly the situation discontinued sectional owners land in.
How much do custom sectional cushions cost?
From $39 make-base plus area at per-sq-ft rates — foam $10.29–$20.25 per square foot by density grade, fabric $3.35–$5.59 by tier — so the set price is driven by the number of blocks and their square footage, not by the sectional being a sectional.
Should I replace just the worn blocks or the whole set?
Replace in symmetry pairs at minimum — adjacent new and old cushions differ visibly in loft — and go full set when more than half the blocks need work.
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.
- Cut to ± ½ inch of your confirmed dimensions, in writing — outside tolerance, remade free.
Related categories
- RV & Camper Cushions — block-by-block measuring at vehicle scale
- Dining Chair Cushions — small-seat precision, house scale
Further reading from the blog
- Sectional cushion replacement: the complete guide — covers, inserts and full cushions by the block — the article behind this page
- How to measure a T-cushion sofa — arms, wings and the notches that trip up tape measures
- Where to buy replacement couch cushions — every option compared
