16" x 16" Outdoor Chair Cushions – Custom Made to Your Exact Size

Cut to your measurements — width, depth, and thickness — not to a stock chart. Factory-direct, no minimums.

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.

Trace your old cushion on paper, photograph it next to a tape measure, and email it to us — a Custom Template order is routine work here.

Enter your measurements

Measure the old cushion flat, edge to edge — never the frame.

Units in — decimals (23.5) or fractions (23 1/2)

Foam density How to choose density →

Your cushion drawing appears here as you type.

Choose your fabric

Six 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.

Use:

Pattern:

All covers sewn to your exact dimensions — no stock sizes, no zippers (sewn envelope closure).

Review & order

Calculated live from your measurements — every line, no surprises.

Price breakdown

Estimates only — we re-verify every dimension before cutting and will contact you if anything looks off. Prefer email? Email me this quote

Your cushion

Your configuration

Factory Direct

Source workshop, no middlemen

119 Fabrics

Free swatch program

±½″ Tolerance

Cut to your exact measurements

Remake Free

If we cut it wrong, remade free

Build Your 16 x 16 Cushion

The 16-inch square is the smallest size most outdoor chairs ask for — bistro chairs, balcony seating, kids’ patio chairs, and the compact frames of stacked dining sets. Small pads are also the hardest to buy off the shelf: stores stock the popular middle sizes and skip the ends of the range, leaving small-frame owners with pads that overhang or gap.

We cut every 16 x 16 outdoor chair cushion to the measurements you send — width, depth, and thickness — in three fabric tiers: Tech Fabric, our leather-like waterproof weave that wipes clean — the outdoor workhorse; Cotton Linen, a durable everyday weave for covered porches and indoors; or Premium Velvet, plush claw-resistant velvet for indoor luxury. At this scale thickness matters more than usual: 2.5″–3″ keeps a bistro chair at its designed seat height, while a 4″ pad can lift a small frame awkwardly high.

Close but not exactly 16 x 16? Type your numbers — decimals included — and the estimate updates as you go →

Pricing — estimated starting at

Fabric tier	Estimated price*
Cotton Linen	$73
Tech Fabric	$85
Premium Velvet	$100

*One cushion, 16 × 16 in. (1.78 sq ft top surface): $39 make-base + 1.78 sq ft × fabric rate ($19.0/sq ft, $25.5/sq ft, $34.0/sq ft). Thickness, foam density, and the sewn closure is confirmed at checkout — and every dimension is confirmed with you before we cut.

For comparison: U.S. custom-configurator specialists’ 2026 listings for made-to-order cushions in common sizes (16×16 through 24×24) run roughly $71–$119 before shipping — and most only reveal that price after a quote request. We publish the formula above so you can check the math before you order.

What fits a 16 x 16 cushion?

No factory-original cushion in our measurement library lands within ¾″ of this size yet — which makes a 16 x 16 a true custom order, and custom orders are our whole business. Measure your old cushion flat (edge to edge, seam to seam), or measure the seat deck between the frame rails, and send us the numbers. We cut to whatever you measured — the quarter inch included — in any fabric tier, any thickness, one piece or a full set.

No factory-original in the measurement library lands at 16 x 16 — brand patio lines start their seat squares at 17–18 inches, so a 16-inch deck is almost always a bistro set, a vintage chair, or an import. The practical neighbors are the 15 x 15 and 17 x 17 pages and the dining chair cushions category; any documented piece can be ordered a fraction smaller at the same formula price.

Yours differs? That’s the point — we cut to your numbers.

How to measure a 16 x 16 cushion

Old cushion flat on a table: width edge to edge, depth front to back, thickness seam to seam — never squeezed.
No old cushion? Measure the seat deck between the frame rails and arms, and send the raw numbers rather than rounding.
Photograph the label under the frame first — a model number can match you to a documented series chart in seconds.

Full walkthrough with photos: How to Measure (and Identify) Your Cushions.

Fabric Options at 16 x 16

Bistro pads live close to food, so cleanability leads: Tech Fabric wipes off the espresso and the ketchup in one pass and takes the weather that comes with outdoor café duty. Cotton Linen suits covered porches and indoor kitchen chairs; Premium Velvet takes dressing benches and formal rooms. All three tiers price on the same area formula at this size, so choose by lifestyle — the full tier logic is in the outdoor fabric guide.

From the 119-fabric swatch library — free samples ship with every quote.

The small-size ladder: 15, 16, 17, 18

Thickness and density at 16 x 16

Sixteen-inch squares are bistro and compact-chair territory, and thickness is mostly a clearance question: bistro sets fold, café chairs sit at standard table height, and both punish pads that lift the sitter past the table lip. Two to 2.5 inches is the working range; 3 inches for chairs you actually sit in for an afternoon. The original pad’s edge height, measured seam to seam, is the number to match when in doubt.

Density at this size follows hours-of-use: 35D honestly covers the occasional balcony pair, 50D is the daily-breakfast standard, and the higher grades are better spent elsewhere. Every grade is cut to your confirmed dimensions — small does not mean less precise, and a quarter inch is a bigger fraction of 16 than of 26.

Small squares form a ladder, and the rungs sit closer together than the numbers suggest — at this scale, half an inch of error is a visible fraction of the pad. Fifteen is stool country: counter and bar decks, mostly indoor. Sixteen is the compact outdoor chair: bistro, café, and the small frames of stacked dining sets. Seventeen runs bistro-and-balcony imports and older European-cut frames. Eighteen is the mainstream floor — the small square that retail actually stocks, and the last rung before the 20-inch default. If your tape reads between rungs — 15.5, 16.5, 17.5 — that is the order; the ladder organizes pages, not cutting forms.

The honest note on skipping rungs: a 16-inch pad on a 17-inch deck gaps at the rails and shifts; an 18 on a 16-inch frame overhangs both edges and rides up. Small frames hide nothing.

Wind, and small decks

Small pads are light, and light pads fly. A 16-inch square in a gust lifts off a smooth deck easier than any lounge cushion — less mass, less friction — and the classic scene is the bistro set rearranging itself across a patio overnight. The honest answers: an exact-fit cut (a pad cut to your confirmed numbers sits far better than a loose stock square), bringing pads inside when wind is forecast, and on smooth resin or metal decks, a thin non-slip rug pad trimmed slightly smaller than the cushion, laid flat underneath, is the honest fix.

A draw from the 119-fabric swatch library — free samples ship with every quote.

Frequently asked questions

How do I clean and care for the fabric?

Spot clean is the rule — every cover is sewn closed, so plan on wipes, not machine washing. Tech Fabric is the easy one: a waterproof surface that wipes clean with a damp cloth. Cotton Linen spot-cleans, with a low-heat iron on the reverse if it creases. Velvet can be dry cleaned or gently hand washed, brushing the pile flat to dry; Chenille is spot clean only — never brush the tufts. Free fabric samples ship with every quote, so you can judge the weave by hand before you commit.

What fabric options are available?

All three tiers, at every size: Tech Fabric, our waterproof, wipe-clean leather-like weave — the outdoor workhorse; Cotton Linen, a durable everyday weave for covered porches and indoors; and Premium Velvet, plush claw-resistant velvet for indoor luxury. The same fabrics at 16 inches as at 60.

Will a 16 x 16 cushion fit a bistro chair exactly?

Only if your chair measures 16 inches — many bistro frames run 15.5 to 17. Measure the seat deck and we cut to your number, not the label.

What chair sizes are close to 16 x 16?

Bistro and café frames run 15–17 inch decks; our library’s nearest documented squares start at 18.25 (the Martha Stewart Charlottetown dining chair, listed on the 18 x 18 page). If your chair is a named Home Depot or IKEA line, try the replacement library before measuring.

How do I keep the cushion in place?

A snug, exact fit does most of the work — a pad cut to your confirmed numbers sits the deck without wandering. We don’t sew on ties or gripper undersides — our factory can’t supply them reliably, so we won’t sell you the promise. For frames that get dragged around, a thin non-slip rug pad trimmed slightly smaller than the cushion, laid flat underneath, is the honest fix.

What size is closest to 16 x 16?

Bistro and café frames run 15–17 inch decks, so the neighbors are close: 15 x 15 for stools and counter seats, 17 x 17 for balcony and import frames, 18 x 18 where retail’s small square begins. Measure first — at this scale a half inch of error is a fitting problem, not a rounding note.

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 16 x 16 cushions from $73 — quote in 4 steps.

Ready when you are. Enter your measurements, pick a fabric tier and your finishing — every dimension comes back to you for confirmation before we cut. One cushion or a whole set, from the factory that ships them. Cut to within ½ inch of your confirmed numbers — outside tolerance, remade free.