Thick Outdoor Cushions — 4-8 Inch High-Density Custom Cut
From:
$111.00
- 4–8 inch lofts on 50–65D high-resilience cores — loft and density both stated, per order.
- Cut to your exact measurements — seat deck numbers plus the loft you choose.
- Made in 4–7 days, rush 3–5 — concrete numbers, not “plush” ad copy.
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.
Loft you feel, density that holds
Thin is the default failure of outdoor seating: 2-inch pads that flatten to an inch under load and leave you sitting on the slats by June. The fix is not a better cover — it is loft plus density. Thick outdoor cushions are built on 4–8 inch high-resilience foam cores at 50–65D, and this page is how to pick the two numbers that decide how the seat feels for the next decade.
Open the Customizer — Outdoor Preselected →
Thick is two numbers: loft and density
Loft is the height of the foam — 4 inches reads as a substantial seat, 5–6 is the deep-seating standard, 7–8 is the sink-in lounger tier that swallow-you comfort is made of. Density is the pounds-per-cubic-foot the foam carries: our 50D sits in the 2.8–3 lb high-resilience class that holds its shape for years, 60–65D is the extra-firm tier for heavy daily use. A thick pad in soft foam is a cushion that goes thin the first month; a firm pad without loft never feels generous at all.
Buyers ask us for concrete numbers because the market rarely gives them — “plush” and “luxurious” are not specifications. Ours are: every order states thickness in inches and density on the D scale, re-verified against your measurements before cutting. The full ratings decoder is in foam density explained.
Choosing your thickness: 4, 6 or 8 inches
Density rides on top of that choice: 50D high-resilience is the right default for seats that get used daily, 60–65D is the extra-firm build for readers who want zero bottoming-out. How to read your own weight and hours-of-use into that call is charted in how to choose foam density, and the outdoor-specific trade between plush HD foam and draining quick-dry foam is in HD vs dry-fast foam.
Measure before you order
Measure first: three minutes with our measuring guide — width, depth, and thickness at the seam, written down per cushion, not per set. Those three numbers are the entire spec: every thick outdoor cushions order we sew is cut to them and nothing else.
Thickness is measured at the seam, tape square to the face — not squeezed at the bulge. On a collapsed old pad, do not measure the foam at all: give us the seat deck width and depth plus the loft you want, and we cut the core to sit proud of the deck. A steel rule across the face, read at eye level, beats a squeezed tape every time.
Related builds: deep seat cushions carries the 23–27 inch deck world in detail, and the fabric side of a thick build — what covers 8 inches of foam in full sun — starts at Sunbrella-class fabrics.
Fabric options & estimated pricing
Every fabric one price, on the same measured cut — so the choice below is about feel and weather, never about the bill. Solution-dyed acrylics for full sun, tech fabrics that shrug a shower, cotton linen for covered spots: all 119 live in the fabric menu inside the order flow.
*USD 45 make-base per piece + area at per-sq-ft rates (foam by density and thickness, fabric flat at $7.43 per sq ft — every one of the 119 fabrics the same rate). Estimates rounded to the dollar; the configurator figures your exact numbers live, and the quote is settled before anything is cut.
Estimates for the typical pieces above; your exact figure is set by your three numbers. Covers close with a zippered closure (covers remove for washing).
What “high-density foam” actually means here
Density is weight per cubic foot, nothing more mystical. Our high-density foam cushions run on 2.8–3 lb HR — high-resilience — cores, roughly the threshold where a seat stops reading as patio filler and starts holding its loft through seasons of sitting. Two clarifications buyers deserve: high density does not mean rock-hard (support firmness is tuned separately, which is how a 3 lb core can still feel plush), and thicker is not automatically denser — an 8-inch block on a light core flattens just as surely as a thin one.
Match the grade to the duty: occasional dining chairs live happily at mid densities, while the 6–8 inch lofts meant for hours of lounging earn the top of the range. The full density ladder, 35D through 65D and what each tier suits, is laid out on our custom cushion inserts page — then measure the seat and price your loft in the customizer.
Frequently asked questions
How thick should outdoor seat cushions be?
Dining-height seating: 3–4 inches so the seat height stays honest. Deep-seating frames: 5–6 inches, the proportion those frames were designed around. Loungers and daybeds: 7–8 for the sink-in tier. Above 6 inches, go 50D or firmer — soft foam that thick wanders at the edges within a season.
Does thicker mean firmer?
No — they are different numbers. Thickness is loft, density is load-bearing. A 6-inch 35D pad feels plush and bottoms out; a 4-inch 65D pad feels firm and unyielding. Thick-and-firm is the combination heavy daily use wants, and it is exactly why we quote both numbers on every order.
Can I get extra-firm cushions?
Yes — 60–65D is our extra-firm tier, roughly the 3 lb high-resilience class and above. Firm-seat builds are the standard answer for readers, big-frame sitters and anyone replacing pads that flattened fast. Same measurements, same fabrics, the density line is a choice in the order flow.
Will an 8-inch cushion fit my frame?
Measure the seat deck, then check what sits in front of it: a thick pad raises the sitting height by its full loft and can crowd a low dining table or an ottoman pairing. If the frame was built for thin pads, 5–6 inches is usually the ceiling; send the three deck numbers and we will flag the fit before cutting.
How much do thick outdoor cushions cost?
Custom pieces start at the USD 111 entry piece in the table above and scale with size and foam density — every fabric one price, final quote confirmed before anything is cut.
How long do they take to make and ship?
Every set is cut and sewn after you order — crafted in 4–7 business days, rush service 3–5 business days, then flat-rate shipping to your door; plan on 3–6 weeks door to door.
What you get ordering from us
- Custom cushion factory for 10+ years — we cut, fill, and sew every order ourselves. Nothing is brokered or dropshipped.
- Before any fabric is unrolled, the measurements you sent are re-verified — three numbers per cushion, checked against the piece count.
- Nothing is stocked — any fabric, any piece, one cushion or forty.
- Outside ±½″ (±¾″ beyond 36″) on our cut, wrong fabric, or wrong build — remade free of charge.
Thick outdoor cushions estimate from $111 (seat pad, 18 × 18 × 4 in., 50D) and scale with loft and density — every fabric one price, the final quote settled at checkout, nothing cut before your numbers are confirmed.
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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