Seats and Cushions - Custom Cut

Use our custom cut cushion service to order replacement seat and sofa cushions to breathe new life into your furniture. Simply select your shape and enter in the dimensions, foam type(s), and quantity, and our team of specialists will craft foam cushions tailor made to your specifications.

Don’t see your shape listed below? We can make nearly any custom shape to special order. Contact Us for details.

Click on a shape to get started!


There is no denying that foam is a versatile material you can use for just about anything. While it can be used for a range of applications in both commercial and residential areas, one of the most common uses is still seating cushions.

With our selection of couch cushions replacements, find the perfect shape for your exact needs at an affordable price. When a sofa has old, flattened cushions or holes in the originals, it can make the seating less supportive and comfortable. Most cushions tend to lose their cushioning appeal over time and become rather thin. The best way to remedy this is with our couch cushion foam inserts. We have a wide selection of foam types and styles for you to choose from with our selection of affordable options.


Return Policy
Custom cushions cannot be accepted for return unless there is a product defect or a manufacturing error. Please see our Return Policy for more information. If you have questions concerning our return policy, please Contact Us before placing your order.

Manufacturing Tolerances
Custom-cut seats and cushions have dimensional tolerances according to the "Custom-Cut Cushions" section of our Dimensional Tolerances table. If your project requires a tighter tolerence, Contact Us for more information about machine cut custom items.

Largest Solid Sheet
The largest solid size available is 76" x 82". When any one piece of foam is ordered larger than that, it will be glued together with another piece. There are no additional gluing charges for oversized cushions.

Largest Solid Thickness
The largest solid thickness available is 6". When any one piece of foam is ordered at a greater thickness than that, it will be glued together with another piece. Up to 8" thickness, there are no additional gluing charges. For thicknesses greater than 8", an additional gluing charge will apply.

Write a Review

Excellent service and guidance, great results
Martha | January 9th, 2020
I ordered a custom cushion for a built-in dining area bench. The website descriptions of the foam selections available were very good and the measuring instructions helped me determine the exact size to order. It was a perfect fit and exactly what our seamstress asked us to provide. The option for a dacron wrap was a plus, as well as the price. I will be contacting the company for additional projects and have recommended the company to others.
Bill | January 8th, 2020
The quality of the foam is exceptional and the precision cut perfect. This is the second time I have used foam factory. This was a very large piece and it was cut perfectly. It was a quick delivery and packed extremely well. Don't hesitate this is a quality product at a great price.
Refreshed the sofa
Paul J | January 8th, 2020
The cushions fit perfectly and have refreshed the sofa to be better than new. The best was very little smell from the cushions and after I left them out for decompressing there was no smell at all.
Excellent service and quality
Arthur I Laursen | January 2nd, 2020
I replaced the foam in my Thomasville couch and love seat after 17 years. The original fabric was their highest quality and now they are back to like new again. I also replaced the cushions in our 6 dining room chairs. My wife absolutely loved the results!
Did the job
Gary | January 2nd, 2020
Very happy with the replacement foam for a couch cushion that I purchased. Will definitely use this product in the future if and when needed.
Alicia Angeli | January 8th, 2020
I was bumming for a long time about my mushy, saggy couch cushions because I thought I would have to DIY replacements. I’m so glad I found this company.. very easy to order, high quality, and super affordable. I couldn’t believe the difference when I started using the new ones. Simply amazing what a difference it made! I couldn’t stop gushing about my new cushions!!
Excellent quality and very fast shipping
Michelle Kline | January 8th, 2020
I bought 4 cushions to replace some very worn out cushions in my couch. The cushions that came with my couch were low quality, and lost their support. These are perfect. The came packaged very well and very fast. This saved me from having to spend money I didn't have to replace a 3 year old couch. I should get 5 or more years out of it now.
Custom Cut Foam
Tina | January 6th, 2020
We ordered 6 custom cut foam cushions to replace the cushions on 2 couches. The order arrived promptly and the cushions are perfect! They are firm and really support your back. We are SO happy with our purchase and would definitely recommend this product. If we ever need replacement cushions again, we will be back! They also have wonderful customer service.
Custom cut foam
Janice | January 3rd, 2020
I ordered three pieces of foam to make cushions for a large window seat. I received the shipment promptly and the foam was cut to the perfect size. Now to get busy and get the the covers made!
Like new
TEC | January 3rd, 2020
Fit perfect, restored couch to like new feel.
Perfect fit
Morse Taxon | January 2nd, 2020
We ordered a custom piece of foam to fill in the gap between our new queen mattress, and the waterbed frame into which we installed it. This worked perfectly, and was much easier than cutting the bed short.
Great couch cushion
Rebecca Storz | January 2nd, 2020
Sooo comfy, we absolutely love it!
Refurbishing a daybed
Gary | January 2nd, 2020
Made over a vintage daybed and wanted something comfortable to stretch out on. Ordered your best 8" foam and had it wrapped with dacron. It was delivered quickly (with good communtcation/updates) and was wrapped and bagged (saved the bag for transport). The measurements are spot on and the foam is super comfortable and supportive without being hard. Had shopped around locally but foambymail's prices could not be beat, not by a long shot. Extremely happy with this purchase and have recommended to friends. Would order from foambymail again in a heartbeat. All around, a great experience.
Great Save for Loveseat
Peggy Richter | December 30th, 2019
I too was a bit nervous about my measurements but cushion arrived and fit perfectly - thanks for extending life of vintage loveseat
We love Foam by Mail!
Deeana’s Designs | December 18th, 2019
I’ve been using foam by mail for ALL of my company’s foam needs for the past couple of years. They have the best prices along with quality, great customer service and free shipping. What’s not to love?!?!
Very pleased
Muddy | December 18th, 2019
Great product. Now I should be able to get a few more years out of my upholstered furniture.
Great deal
William Miller | December 18th, 2019
We ordered new cushions for our 2 couches, the process was easy, delivered no problem, installed they are great
Great Work
Deborah Bones | December 18th, 2019
Great! Saved my favorite couch with these new cushions. Great product .....timely service and well done!ork
3 Orders!
Mike E | December 18th, 2019
Three orders. Three great results. Terrific customer service. Revitalized couch! Couldn't be happier with Foam Factory!
Exactly Right
Sherrill | December 18th, 2019
Needed a supportive "topper" for our RV futon. This should be just right. Will use Foam Factory again, if needed, knowing I can order just what I need and receive a great product in a very timely manner.
Replaced 10 year old loveseat cushions
William Martin | December 18th, 2019
The loveseat sits better now than when it was new. Will probably replace the sofa cushions one day as well.
The new look
Gregoree | December 18th, 2019
After receiving my new cushions from the foam factory and installing them on my sofa it was like night and day. My wife couldn't believe the difference it made so she slept on the sofa overnight to test it and said she loved it. She said she had forgotten how it was suppose to be....
great replacement
Craig | December 19th, 2019
brought the sofa back to life. Perfect way to update and improve comfort.
Nice short cut
Jeanenne | December 20th, 2019
I appreciate this custom cut service, especially when I need multiple cushions in varying thicknesses and densities. This keeps the cost and scrap foam to a minimum.
foam for chairs
CATHERINE LARKINS | December 20th, 2019
It was great to order foam cushions the right size, already wrapped. Just had to pull out the old worn out cushion and put these new ones in. Thanks.
Replaced 20+ year old sofa cushions
Mary | December 26th, 2019
So happy I ordered replacement cushions for a sofa I love. I had started looking for a new sofa since my cushions had become so saggy that the sofa was killing my back. This was a wonderful, budget-friendly alternative to getting a new sofa that I did not want anyway. Love my old sofa and now it looks and feels perfect. Thank you so much!!
Great replacement
Britteny | December 26th, 2019
I ordered these to replace the seat inserts for our leather sofa that had been worn out. It was a little bit of a workout to get them in since the leather is unforgiving, but once in, they were PERFECT. They are the right firmness for my bad back and very comfortable.
Excellent product and service😋
Mary Carver | December 26th, 2019
Excellent product, customer service, & timely delivery. We are extremely satisfied and have referred your company to several people and will continue to do so. Thank you!!!
Foam by mail? - of course!
Missy | December 26th, 2019
I contacted Foam by Mail with questions about ordering, and Amy got back to me quickly with measuring instructions. Of course, I was still nervous that my measurements would be off, and my new cushions would be just as bad as the old. I was so wrong! I ordered the cushions online ( L-shapes), followed the measuring instructions, and I couldn’t be happier with what arrived a couple of weeks later. My couch was saved! Thanks Foam by Mail!
Perfect solution for my couch
Kieran | December 26th, 2019
Was worried about my measurements but the replacement couch cushions came and fit in the slip covers perfectly. It's like I have a whole new couch. this was the perfect solution!!
Great product
Patrick Wicichowski | December 26th, 2019
Great product and fast shipping .
Sofa & Chair like new again!
Sherri Sullivan | December 26th, 2019
My Mom's old sofa and chair was over 20+ years old but still looked new except for the cusions were crumbling apart like sawdust & very uncomfortable to sit. Replacing the cusions with your cusions has given us "like new" sofa and chair. Cusions are well made, very comfortable, & the fit was PERFECT! Foam by mail made the instructions for measuring easy and they were very prompt with my order. Thank You!!!
Cushion, Lux Foam - Regular WITH DACRON WRAP
Christina Seelen | December 11th, 2019
I am thrilled with my inserts! They arrived quicker than I thought they would and are the firmness I was looking for. Thank you!
RV Cushions
Marc Bellacosa | December 11th, 2019
Cushions came out just as described. The quality was great!
Katrina Stumpf | December 11th, 2019
The cushions arrived quickly and as advertised. They fit perfectly. I wish I had done it sooner!
I've been using Foam Factory for years!
Cathy Silverberg | December 11th, 2019
I am a sewing company and use foam factory for all my customer's cushions, including our church pew cushions we recovered two years ago. Highly recommend this company. Service and product wonderful. Fast ship. The only con I have is they staple the dacron on, rather than use adhesive.
Perfect Fit!
Peter C | December 11th, 2019
Easy to order, quick shipping and excellent fit. Great experience!
Highly recommended
Angie | December 11th, 2019
I ordered 5 seat cushions for sectional couch. Everything was perfect. It’s only been a month but I am very pleased.
New Life To Old Victorian
Pat Aleo | December 12th, 2019
Mother's old Victorian love seat was shoved in the back room never to be used again because the cushions were broken down. The fabric and wood trim was still like new. We replaced the cushions with customized cut foam forms from the Foam Factory and couldn't be more pleased; they were cut exactly as ordered and arrived earlier than expected. Mom is now using the love seat in the living room of her assisted care facility where she now resides and everyone who visits comments on how nice the love seat looks and sits for its age. I will certainly remember the Foam Factory for future needs.
Kim Ronnisch | December 13th, 2019
Great product! I have a sectional that is more than 15 years old, the fabric is still perfect but the cushions had “deflated”! I still love the fabric but wanted a way to replace the cushions. Foam Factory to the rescue! I followed the measuring instructions exactly, entered them online in minutes, and a few days later they arrived! They were vac packed and easy to open. I unzipped the covers, removed my old cushions and inserted the new. Easy peasy and this couch is better than it was new! The foam is high quality and I got mine wrapped in Dacron. If you are in my situation and still love your furniture but it needs new cushions, do not hesitate. You will be thrilled with the outcome!
New cushions are great!
Lisa | December 4th, 2019
I ordered 4 LUX foam cushions in 2 different sizes to redo my sofa and loveseat cushions. The order arrived quickly and I loved that they were cut to size. My new cushions are fabulous!
Bench Cushion
Kathleen Farmer | December 4th, 2019
I ordered a foam rectangle for a bench. It fits perfectly. I went with the suggestion to have it wrapped and that really adds to our soft the cushion is. Many thanks.
Cushion, HD36 Foam - High Quality
linda smith-houston | December 4th, 2019
2" x 22"x 192" - shippng fast and quality is great. So glad I found you all.
New couch cushions
Beth Walen | December 4th, 2019
I ordered the luxury high density cushions. They are wonderful! Perfect fit. Easy to order. Arrived promptly. I'm telling everyone about this company. Thank you!
Highly recommended
Wib Elliott | December 4th, 2019
Custom fit like a glove and made my sectional look and feel like new again. Thanks much for the super fast shipping!
Sofa cushions
Lou | December 4th, 2019
I ordered three sofa cushions with Dacron wraps and they made my 30 year old sleeper sofa feel like new again. I will definitely order again when I need to replace my porch cushions.
Great Cushions
Kimberly Coble | December 4th, 2019
Overall, prices are great compared to other foam companies and so is the free shipping. The cushion arrived properly packaged in a timely manner. The dacron is a little loosely fit for my preferences. Handle with extreme care as not to pull it off the cushion.
I love Foam Factory. I have a workroom in NJ and anytime I have a project that requires foam I order from foam factory.
Robin Fontaine-Matthews | December 4th, 2019
I ordered 3" foam
MARION | December 4th, 2019
Cushion, HD36 Foam - High Quality 4x16x16 Wasn't sure what to order but this turned out perfect as a cushion for my desk chair ... so comfy !
Glad I Did It!
wayne bitting | December 5th, 2019
Bought five 5" thick Lux with the Dacron wrap foam cushions and for $200 I was able to make out couch and love seat usable again - no more sinking in and back aches! I used Foam Factory for packing foam at work too and was always happy.