Custom Sectional Cushions

Build Your Sectional Cushion

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.

Open the Customizer — T-Cushion Preselected →

Enter each block’s outline — T-cushion arms take the notched outline — then pick your fabric tier and order the family in one run.

Need a different shape? Start from all 11 shapes →

Pricing — estimated starting at

*One seat block (24 × 25 × 5 in.): $45 make-base + 4.2 sq ft × rate ($30.79 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. The pricing math is right on the page — every dollar of the estimate traces back to a dimension you can measure.

Popular Sectional Sizes We Cut

The blocks a typical L-shaped sectional breaks down into (typical, always measure).

<p class="Yours differs? That’s the point — we cut to your numbers.“>dim-note

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.

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 — complete replacement couch cushions in one run. 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.

Sectionals We Build For

• The L-shaped patio sectional — straight seat blocks plus a corner wedge with two different depths; counted and named as a floor plan before anything is measured.
• The chaise-end sectional — one long rectangle or an L-shaped piece cut as one, not two; the corner and chaise blocks carry the most concentrated lounging, so they are the wrong blocks to economize on.
• T-cushion arms and hinged sleepers — notched outlines sketched on paper, hinge lines measured as the dimension they are; every block in one fabric run.

See all fabrics — pick by look, not budget — in the customizer.

Frequently asked questions

Can I order standard sectional cushion sizes?

Yes — 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 $45 make-base plus area at per-sq-ft rates — foam $15.99–$31.47 per square foot by density grade and thickness, fabric $6.93 flat across all fabrics — 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.

How long does a custom cushion take?

Made to order in 4–7 business days — rush production is 3–5 business days for a surcharge — delivered in 3–6 weeks door to door. Typical US custom shops quote 3–6 weeks for the same build; we publish the number instead of burying it in a quote.

Is a Custom Sectional Cushion Set Right for You?

• One new block among old ones shows. New foam sits at full loft and dye lots drift between runs — a single fresh block next to dished originals is visible from across the room. Replace in symmetry pairs at minimum, and plan the full set when more than half the blocks are gone.
• Machine washing is not on the menu. Every cover closes with a zipper around its foam, so the cleaning spec is a damp cloth and mild soap between washes — and a cover-off wash when due. A machine cycle is how a custom cushion dies years early.
• Custom-cut means non-returnable. A pad cut to your numbers fits exactly one frame on earth. Tolerances are published in writing (±½″, ±¾″ over 36″); anything outside them against your confirmed numbers is remade free, whenever the error is found.

Related guide

Buying new or reviving what you own? Sectional Cushion Replacement runs the block-by-block cost math against a new L-shaped sofa, the 30-second decision test, and how to measure every block as a family.

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.
• If we cut it wrong — outside the ±½″ tolerance (±¾″ over 36″), wrong fabric, wrong build — remade free.

Custom outdoor sectional cushions from $162 per block — quote in 4 steps.