Custom Rectangle Cushions — Cut to Your Three Numbers
Rectangle cushions are the workhorse shape — kitchen chairs, benches, window seats, daybeds, boat berths. Whatever furniture holds a straight-edged pad, we cut it to the exact width, depth, and thickness you measure, never to a size chart. Factory pads go thin and soft years before the frame gives out, and store replacements come in whole-inch sizes that never match the odd measurements real furniture has. Send three numbers per piece and a photo, and high-density foam in the fabric you pick arrives ready to drop in.
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
Width, depth, thickness — seam to seam, never a size-chart guess
Miss on our side and the remake is free
Why Rectangle Cushions Are the Easiest Custom Win
The rectangle is the most-replaced cushion shape there is, because most furniture seats are straight-edged boxes. And it is where factory pads cut the hardest corners: thin foam, low density, and dimensions like 16 3/4 or 17 1/4 inches that no shelf ever stocked. The big-box answer is to round you to the nearest whole inch and let a half-inch of slop slide around under whoever sits down.
The failure pattern is predictable. A pad even slightly small shifts every time someone stands up; a pad even slightly large puckers at the corners. Once the foam flattens, the cover goes loose as well, and a rectangle that used to look tailored starts reading as a sack. The frame underneath — solid wood, sound rails, good springs — routinely outlives two sets of pads.
Rectangles are also the friendliest shape to order custom. Three numbers describe the whole piece, two diagonals prove it square, and there is no curve or corner geometry to negotiate. The same $45 cutting charge that buys a bespoke odd-shape buys your rectangle: custom is cheapest exactly where most people never try it.
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 dimensions in real time — no quote wait, no email ping-pong before you see a number.
| Big-box universal pad | Cushion Mill custom cut | |
|---|---|---|
| Fit | Close enough — gaps, overhangs | Your measurements, ±½″ |
| Foam | Fixed low-density fill | 35D / 50D / 60D, your choice |
| Fabric | 3–5 colorways | 119 fabrics, one flat rate |
| Fractional sizes | 16 3/4 in.? Buy the 17 and hope | Any fraction, cut to the number |
| When it wears | Buy a new set, same bad fit | Re-cut the same specs in minutes |
Rectangle Cushion Dimensions — What We Typically See
| Piece | Typical range | Notes |
|---|---|---|
| Kitchen or dining chair pad | 16–19 in. W × 16–18 in. D × 2–3 in. T | 17 × 17 in. is the classic; fractions are the norm, not the exception |
| Indoor bench pad | 36–60 in. W × 16–20 in. D × 3–4 in. T | Entryway benches and hallway runners; long runs can split into sections |
| Window seat pad | Up to 96 in. W × 18–24 in. D × 4–5 in. T | Single pieces or split sections for storage beneath |
| Daybed / single sleeper | 72–75 in. W × 30–36 in. D × 4–6 in. T | Treat thickness and density as a mattress decision |
Pricing — estimated starting at
| Piece | Example size (W × D × T) | Foam | Estimated price* |
|---|---|---|---|
| Chair pad | 17 × 17 × 2 in. | 50D | $92 |
| Bench pad | 48 × 18 × 3 in. | 50D | $201 |
| Window seat pad | 72 × 20 × 4 in. | 50D | $335 |
| Daybed mattress | 75 × 32 × 5 in. | 60D | $600 |
*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. Change the thickness or density in the tool and the price updates instantly — these anchors are honest arithmetic, not teaser rates.
Rethinking a whole room? Chair pads, bench pads, window seats, and mattress toppers can ship in one order, and the customizer prices each piece as you add it — no bundle guesswork.
Foam & Thickness for Rectangle Duty
| Foam | Best for | Typical thickness |
|---|---|---|
| 35D | Occasional chairs, guest-room seating | 2–3 in. |
| 50D | Everyday chairs and benches | 3–4 in. |
| 60D | Window seats slept on, daybeds | 4–6 in. |
For a pad that gets sat on every day, 50D at three inches is the honest default. Move up to 60D when the rectangle doubles as a bed — window seats and daybeds only hold a sleeping body with denser foam. And add density before you add width: a firm 3-inch pad outlasts a soft 5-inch one by years.
How to Measure a Rectangle Cushion
Take the old pad off the furniture and lay it flat — measuring in place hides the edges that matter.
- Width — seam to seam, left to right, tape flat on the fabric.
- Depth — front seam to back seam, top to bottom of the sitting surface.
- Thickness — bottom to top with the foam resting naturally, not squeezed.
Then the rectangle-specific check: measure both diagonals, corner to corner. Matching diagonals within a quarter inch mean the piece is truly square and your three numbers describe it completely. If one diagonal runs longer, note which — the old cover was cut slightly off-square and we can true it on the new cut. One photo beside a tape measure catches anything the numbers miss. We cut to a ±½″ tolerance and remake free if a piece misses it.
Fabrics for Straightforward Living
A rectangle cushion is often the hardest-used surface in the room — the chair pulled up three times a day, the bench everyone drops bags on. The fabrics that survive are the ones you can live on:
- Tech Fabric — waterproof and wipe-clean, the choice for kitchen chairs and entryway benches.
- Cotton Linen — the soft, natural hand for reading chairs and window seats in mild, dry rooms.
- Pet-friendly weaves — resist snags and claw-pulls and forgive fur on daily-duty seating.
- Chenille & velvet — for pieces whose job is looking good, in rooms where life is calmer.
All 119 options price at the same flat rate, so pick by how the seat lives, not by budget tier. Ordering a spare cover in the same fabric at the same time is a popular move for chairs that see daily meals.
Rectangle Pieces We Cut Every Week
- Kitchen and dining chair pads — the everyday 17-inch square and every fraction around it
- Entryway and hallway bench pads, including extra-long single pieces
- Window seat pads, split into manageable sections when the run is long
- Daybed and sleeper rectangles in mattress densities
- Boat berth and cabin pads cut to your tracings — rectangles with the odd corner notched out
Not every rectangle is a plain rectangle: notched corners for table legs, cutouts for pipe runs, and squares with a corner angled off are all selectable in the customizer. For anything the shape picker can’t express, send a paper template with your order and we cut to the line.
Before You Order — Worth Reading
- How to measure a rectangle cushion — the full walk-through, with the diagonal check explained
- Bench cushion measurements — sizing help for the long pads
- Window seat cushion measurement — long runs and split sections handled
Frequently asked questions
How do I measure a rectangle cushion for replacement?
Seam to seam for width and depth, thickness with the foam at rest, then both diagonals corner to corner to confirm the piece is square. If the diagonals differ by more than a quarter inch, note which is longer — we true the new cut. Add one photo of the piece beside a tape measure. We cut to ±½″ and remake free if a piece misses it.
What’s the difference between ordering a rectangle and a square cushion?
None on the order form — a square is just a rectangle whose width equals its depth. Enter both numbers separately anyway, and measure rather than assume: plenty of “square” chair pads measure 17 by 16 3/4 once the tape comes out.
What thickness should a rectangle seat cushion be?
2–3 inches for chair pads, 3–4 for benches, 4–6 for window seats and daybeds that get slept on. 50D foam is the everyday default; move to 60D when the pad doubles as a bed.
Can I order just the cover, not the foam?
Yes — we sew replacement covers to your seam-to-seam measurements in the same 119 fabrics, with zippers where the original had them. If your old cover still exists, mail it to us and we pattern from it directly. One test before you decide: press the seat hard — if your hand feels the deck through the foam, replace the foam too.
My old pad measures a fraction like 16 3/4 inches. Do I round it?
No — enter the exact fraction. That is the whole point of custom: the big-box store rounds you to 17 and the pad slides; we cut 16 3/4, and the ±½″ tolerance is measured against your number, not against a shelf size.
Will a custom rectangle pad fit my rattan or wicker chair?
Yes, when the seating surface is a flat rectangle. Photograph the frame from above with a tape across it — woven frames sometimes flare at the front edge, and the photo tells us whether to cut the front true or follow the flare with a template.
How do I order several identical chair pads?
Enter the piece once, then repeat it for each chair in the customizer — every piece prices as you add it, identical pieces cost identically, and one order ships together. Ordering all matching chairs in the same order also keeps the fabric from the same bolt.
How long do custom rectangle 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 rectangle cushions from $92 — three numbers per piece in the customizer to a live price. Enter your measurements, pick density and fabric, and the number is on screen before you commit.
Ready when you are. Measure the old pads tonight, enter the numbers, and the chairs are a weekend job from done.