Custom Outdoor Sofa Cushions
From:
$143.00
Replace weathered outdoor sofa cushions with custom-cut ones that fit. Fade-resistant fabrics, dense foam, free remake guarantee.
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
Cut and sewn by the factory that ships them — no middlemen.
One price for every fabric. Pick by look, not budget.
Every dimension re-checked before cutting. Outside tolerance, remade free.
If we cut it wrong, we remake it — no arguments.
Custom outdoor sofa cushions cut to your frame’s real dimensions — deep-seat sections, modular pieces, and full sofa sets. When the originals sun-rot, soak, and flatten, the big-box answer is a new sofa; ours is new cushions that fit the one you already own. Enter your measurements, pick fabric and foam, and the set rebuilds itself in the customizer.
- Factory Direct — The workshop that cuts it is the one that ships it
- 119 Fabrics — Every fabric on the list, open in the configurator
- ±½″ Tolerance — Measured cuts, not stock-chart guesses
- Remake Free — Miss on our side and the remake is free
Why Outdoor Sofa Cushions Die Young
Outdoor cushions fail in a specific order: the fabric UV-cakes and fades, the filling takes on water and never quite gives it back, and somewhere in the second or third season the pad becomes a sponge you sit on politely. The sofa frame underneath — aluminum, teak, steel — is usually good for another decade of weather.
The retail answer to a dead cushion set is discontinuation. Once your sofa’s pattern cycles out of the catalog, the “replacement cushions” search returns nothing that fits: today’s model runs two inches deeper, or the back heights changed, or the corner piece vanished from the lineup entirely. The sofa didn’t break; the aftermarket did.
Custom cutting reverses the equation. Each piece is made from your measurements — seat by seat, back by back, corner by corner — in outdoor-rated fabrics and the density you choose. The frame you liked enough to buy gets the cushions it should have shipped with.
Why order from a mill instead
Every cushion leaves our workshop cut to your entered dimensions, in 119 fabrics at one flat rate, sewn to a quarter-inch tolerance with a free remake guarantee. The customizer above prices the full set piece by piece as you build it.
| Big-box replacement hunt | Cushion Mill custom cut | |
|---|---|---|
| Fit | Discontinued in year two | Your frame, ±½″, forever |
| Set geometry | Corner pieces never match | Every piece quoted separately |
| Fabric | Seasonal palette | 119 fabrics, reorderable |
| Foam | Mystery fill | 35D / 50D / 60D, your choice |
| Next replacement | New sofa | Re-cut your saved specs |
Outdoor Sofa Cushion Dimensions — What We Typically See
| Piece | Documented range | Notes |
|---|---|---|
| Seat cushion (per piece) | 21–26 in. W × 19–27 in. D × 4–6 in. T | Modular sofas cut seats into 2–4 pieces; lounge sections run deepest |
| Back cushion | 20–26 in. W × 15–22 in. H × 3–5 in. T | Usually one per seat piece, occasionally split |
| Full-width loveseat/sofa pad | 45–51 in. W | For frames that take one-piece pads instead of sections |
Pricing — estimated starting at
| Set | Example pieces (W × D × T) | Foam | Estimated price* |
|---|---|---|---|
| Single seat piece | 24 × 24 × 5 in. | 50D | $168 |
| Matching back | 24 × 20 × 4 in. | 50D | $143 |
| Loveseat set | 2 seats + 2 backs | 50D | $622 |
| Three-seat set | 3 seats + 3 backs | 50D | $933 |
*Per piece arithmetic, live in the customizer: $45 cutting per piece, foam by density and thickness, fabric flat at $7.43/sq ft — all 119 outdoor-rated options included. Modular corner pieces price on their own measurements, no set penalty.
Full sectional rebuilds quote the same way: add every seat, back, and corner in one order and the total builds on screen. There is no bundle discount because there is no bundle markup.
Foam & Thickness for Outdoor Sofas
| Foam | Best for | Typical thickness |
|---|---|---|
| 35D | Covered porches, three-season use | 4 in. |
| 50D | Full exposure, daily use | 4–5 in. |
| 60D | The sofa everyone gravitates to | 5–6 in. |
Outdoor comfort is mostly thickness and fabric, in that order. Five inches of 50D turns a sun-rotted set into the seat of the yard; six inches of 60D makes an outdoor sofa people fall asleep on. Under four inches on an exposed patio is a pad you will replace again next year — density is what stops the second dip.
How to Measure Outdoor Sofa Cushions
Measure each piece separately and photograph the layout before you unstack anything.
- Width — seam to seam; for corner pieces, both straight edges.
- Depth — front seam to back seam, tape flat.
- Thickness — bottom to top at rest, uncompressed.
Modular frames: label each piece’s position (left seat, corner, ottoman) on the photo and enter them one by one — the customizer keeps the running total. Deep-seat frames measure to the back rest position, not the frame edge, so the pad doesn’t swallow the seat. Tolerance is ±½″, remake free.
Fabrics That Live Outside
The fabric decides how the set ages; the foam only decides how it sits. For full exposure:
- Tech Fabric — waterproof and wipe-clean; pool chemistry, sunscreen, and drinks are its home field.
- Solution-dyed weaves — the fade tier that keeps color through summers of UV; the outdoor fabric guide compares tiers honestly.
- Pet-friendly weaves — the outdoor sofa the dog has claimed, recovered in something that forgives claws and dries fast.
Light colors show the seasons, patterns hide them — both fade-stable in the outdoor range. Every cover unzips for washing, and covers-only orders are available if the foam still passes the press test.
Outdoor Pieces We Cut
- Seat and back sets for full outdoor sofas and loveseats
- Modular sectional pieces — seats, backs, corners, wedges
- Deep-seat lounge pads
- Ottoman and coffee-table pads to match
- One-piece full-width pads for solid frames
Mixed sets with one dead piece are the most common single order: enter the survivor’s measurements and the new piece arrives indistinguishable in size. Swatches of your saved specs make the third rebuild a two-minute order.
Before You Order — Worth Reading
- Outdoor cushions buying guide — foam, fabric, and fit decisions compared
- When to replace outdoor cushions — the honest end-of-life test
- How to measure outdoor cushions — the illustrated walk-through
Frequently asked questions
How do I measure outdoor sofa cushions?
Per piece: width seam to seam (both straight edges on corners), depth front to back, thickness at rest. Photograph the assembled layout and label each piece before you unstack. Every piece gets entered separately — modular sets vary more than they look.
What happens when it rains?
Water beads and wipes on Tech Fabric; every cover unzips to dry faster after a soaking. For uncovered exposure, prop cushions on edge after storms and store them in the off-season — the care guide covers the routine. Foam density choice affects sit, not drainage.
My sofa is discontinued. Can you still match it?
Yes — that is the majority of our outdoor work. Discontinued means the catalog stopped, not the measuring tape. Your dimensions are the pattern, and we re-cut them any time without a catalog.
Can I order just the cushions for one section of a sectional?
Yes — single pieces are standard orders. Enter the measurements of the dead piece (or its survivor twin) and match or deliberately contrast the fabric; the rest of the set keeps its years.
Do you make covers only, without new foam?
Yes — covers to your seam-to-seam measurements in all 119 fabrics, with zippers. The press test decides: if your hand feels the frame through the foam, replace the foam in the same order.
How thick should outdoor sofa cushions be?
Four to six inches. Four restores a dining-height feel; five is the deep-seat standard; six turns the sofa into a nap destination. Below four, an exposed set is a next-year problem.
How long do custom outdoor sofa cushions take?
Standard builds leave the workshop in 4–7 days, rush builds in 3–5, with shipping typically 3–6 weeks. Large sectional sets confirm dates in the order summary.
Will the colors fade?
All outdoor-range fabrics are built for UV exposure; solution-dyed weaves hold color longest. The fabric guide lays out the honest tiers — the short version: full-sun yards buy the solution-dyed tier, covered porches have wider latitude.
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 outdoor sofa cushions from $143 — the frame is already paid for; the cushions are the renovation.
Ready when you are. Measure the set this weekend; the yard reopens next month.
Related guides
- Custom Sofa Cushions — the indoor sofa guide: seat and back sets for living rooms and family rooms.
Shipping & Delivery
- Orders over $158 ship free — add a second cushion or an upgrade and shipping’s on us.
- Smaller orders ship anywhere in the contiguous US for one simple flat fee — always shown before you pay.
- Made in 7–14 business days. Each cushion is cut and sewn to your measurements after you order, never pulled from a shelf.
- ±½″ tolerance on all custom cuts — and if we cut it wrong, we remake it free. No forms, no fine print.
Have a deadline? Contact us before ordering and we will tell you honestly whether we can meet it.
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- ±½″ tolerance, re-checked before cutting — remade free if we cut it wrong.
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