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.

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New life for RV dinette.
Jan Monger | September 26th, 2019
Extremely happy with my order. Living in a rural community, ordering online saved me from making several trips to search for the right product with correct measurements. Very thankful.
A+ experience
Cheryl | September 25th, 2019
Ordered foam to fill 2 floor cushions. Package arrived much sooner than expected—great!—opened the box that night and foam regained shape almost immediately. Perfect density for my purposes—firm, but with enough give to offer sitting comfort. Affordable and no off-gassing :)
Round Cushion
Susan Shaffer | September 25th, 2019
I bought the round 2x40x40 to put under the cushion of a Papason chair I bought that didn't have enough padding. It really did the trick, and was exactly as described.
Very Satisfied
John McKervey | September 25th, 2019
Dimensions were perfect and foam is very firm and comfortable.
Custom Order
Dawn Andrews | September 18th, 2019
Excellent transaction! Custom order was received much much sooner than projected and it was as ordered :) Would definitely recommend! Actually have.
Great Job
Navid | September 18th, 2019
Good price, on-time delivery, good material
Great Product!
Gale Dickerson | September 18th, 2019
My seat cushion came quickly, and was perfect. The measuring process worked perfectly. Thanks!!
Bench Restoration
Fiona L | August 31st, 2019
I bought the High Quality Lux Foam in the 2" depth for a 100+ year old bench I was restoring. The springs on it went rather high, so I went with the firmest best foam I could find. I didn't trust myself to get the measurements perfect online, so I added a couple extra inches and trimmed accordingly with an electric carving knife (lol). Very pleased with how the bench turned out. It's very comfortable and the perfect density.
Great Product! Great Service!
Fred Muller | September 4th, 2019
This is the first time I bought from Foam Factory and it won't be the last. Awesome customer service and fair prices, and I had the seat cushions custom cut for our dining room chaits. AAAAAA++++++
Custom cut foam
Noel A Veglahn | September 4th, 2019
Fast delivery and cutom cuts were right on. Excelent product and great comunications from company
First time purchase
Jodi | September 4th, 2019
This was my first time using this website. We bought a camper and needed to replace the cushions. I wasn't exactly sure how to order what we needed. This website made it so easy. We received our order and the cushions were perfect!
Great foam cushion replacement
Jackie Kever | September 4th, 2019
The foam cushion replacement was spot on. The foam was the exact density (after a suggestion from Foam Factory). It shipped quickly also.
Great product!
Paula | September 4th, 2019
I am so glad that I chose this company. The replacement cushions fit perfectly and I have a "new" sofa and chair for the price of replacement foam. Couldn't be happier.
Great resource
Michael Murphy | September 6th, 2019
We just moved and I haven't been able to find an upholsterer yet and needed new cushions for some chairs. I found several sites that offered custom cushions, but offered the best pricing and the best measuring. They offered the rounded T-Cushion and 5 points of measurement, while others only offered 3 or 4 points. This was perfect. Our cushions were sent out, shrink wrapped, and arrived in perfect condition. They fit like a glove and the client is extatic. We are too. I'm definitely keeping them on my Gold list of prefered vendors.
Custom Cushions
Lisa B. | September 6th, 2019
I ordered custom cushions and my leather sectional is like new! The cost was reasonable and the foam is high quality. Will definitely use the Foam Factory for all my cushion needs.
Couch and chair cushions
Sheila | September 6th, 2019
I have ordered custom cut and Dacron wrapped cushion three separate times. I was surprisingly pleased with the selection and ultimately the quality of these cushions.
I am happy with my new cushions.
Shannon | September 11th, 2019
I was directed to purchase a cushion from, by my upholstery teacher. I decided to replace my cushions for my dining room set. They are just great. The fit on my seats is excellent. I would purchase foam seats again from
Best of the Best
Bobby | September 11th, 2019
Extremely happy with the product I purchased. The pillows were exactly what I expected. High Quality and Well packaged for shipment. We wanted a stiff cushion and these do not disappoint. Will order again in the future when I tackle another project. Keep up the great work and customer support.
Repeat Customer
penny | September 11th, 2019
Good quality, good prices. Don't purchase foam ofter but each time I've been in the market, I've researched around and have gone back to Foam Factory.
couch like new
KBird | July 19th, 2019
Love love love. These were easy and fast to order. They fit great and have completely changed the feeling of our couch. Wish we had done this sooner.
Chairs like new
Denise | July 21st, 2019
Reasonable price, great stiff foam--what I was looking for. I would buy from them again.
Great products and customer service
Pamela Hoffman | July 21st, 2019
I highly recommend this company for all your foam/batting needs. The prices are very reasonable. The turn around time for shipping is excellent. AND, I love opening the packages and watching the foam “explode” as it expands! It is amazing to me too seed how compacted the products are when they arrive. Thank you for your excellent product and service.
Very pleased
Linda Bucki | July 30th, 2019
I ordered replacement cushions for my sofa and couldn’t be more pleased. The descriptions of the foam were spot on. The cushions were nicely wrapped with batting and the sizing was as I requested. Price was great. I highly recommend them for all your foam needs.
Lucille Knapp | August 28th, 2019
smaller package, opens up really quickly and gets to full size very fast. Great product. thanks.
Great product that also saves you $$$.
Faraz A | August 28th, 2019
Great experience in upgrading my couch cushions. Team at Foam factory was fantastic in explaining different materials and with their help, I was able to order firm cushions for my couch to help my ailing mother easily get up from the couch at a fraction of the cost compared to buying a new couch.
Parish Administrator
V. Smith | August 28th, 2019
We were very pleased with the product we ordered. It was easier to order to custom size than to buy a large roll and get stuck with alot of leftovers. Shipped and delivered in the time frame promised.
New life for my living room furniture
Jasen | August 28th, 2019
I had a nice set of leather furniture (couch, love seat, and chair) that I've had for close to 15 years. In that time, the cushions had lost their "springy-ness" and began to sag. After purchasing this replacement foam, my couch is like new again. The cushions are probably better than the original and are so comfortable. This probably bought me another 15 yrs with this classically styled furniture. Fantastic purchase!.
Love my new cushions
Alena | August 28th, 2019
Needed to add firmness to my couch ordered cushions through Foam Factory and Love the fact that I can now sit on my couch and not sink in and kill my back. Received help from customer service rep Jeremy. Thank you :)
Saved $1500
Therese | August 28th, 2019
Brought our 5 year old couch back to life and saved us from buying a new couch. I measured only from seam to seam and did not add anything extra. We like a firmer support and chose Lux High Quality. Make sure to get the Dacron wrap, it's worth and they do it right. Put the cushions back in the cover as soon as you can when they arrive. They will firm up and puff up a little bit since they are compressed when shipped. Great company!
Happy with my cushions
Barbara A Lippert | August 28th, 2019
My sofa is about 10 years old and the cushions had become too soft. I thought I needed a new sofa, but I took a chance and ordered replacement cushions- they arrived very quickly and my sofa feels new again!
Self Employed
Tanya Barnes | August 29th, 2019
We needed a new mattress for a bunk bed in a travel trailer. Finding a suitable mattress that was the right size and thick enough for comfort was very challenging. I came across Foam Factory and was a bit apprehensive to order online without seeing and touching the product, but the website was amazing with very clear photos and descriptions. This whole experience has been amazing! The foam mattress was everything we expected. The shipping was prompt and the package was well-sealed. We opened it right away and it was fully expanded within 24 hours. I highly recommend Foam Factory! Thanks!
New Airstream seat cushions
Ronnie Dennis | August 29th, 2019
Ordered Lux-HD 5” foam to replace the soft foam in the factory seat cushions of my Airstream Travel trailer. Super fast shipping and great product.
Convenient online orders of cushions
Ahmad Ibrahim | July 10th, 2019
Convenient online cushions order, was a very easy and simple online ordering to replace cushions for my outdoor chair set, very first shipment. Thank you
Replaced dinette cushion in Travel Trailer (RPOD)
Paul Chen | July 10th, 2019
Recently i replaced the factory cushion in my RPOD 179 model. It was 3 years old, but didn't realize how much sagging had taken place. Thanks to a DIY video (, I decided to try it myself and it's super easy thanks to The Foam Factory. :)
Great Product, fast delivery
Deni | July 10th, 2019
Ordered this late on Friday afternoon and had less than a week later. Very good quality cushion foam. Used it for seat cushions in my RV to replace old, worn seats.
Darlene Messina | July 10th, 2019
We love our custom sleeping porch mattress from Foam Factory. Since our antique sleeping cot was not a standard size, the Foam Factory was the perfect choice. I had the Dacron cover added and the bed is so comfy. The service was excellent and the product superior.
New cushions make LIKE NEW couch
Sharon | July 10th, 2019
These cushions were perfect in my 20 year old leather couch. It literally looks and feels like a new one. I was hesitant at first bu sooo...happy with my purchase
Just right
Joy | July 10th, 2019
Ordered 6 chair cushions and received them right on time and they met my expectations. Great product!
Great quality and service
Eva Morelli | July 10th, 2019
The cushions were exactly as described and also were exactly the measurements I provided and wanted. Perfect ,will definitely use foam by mail again. Great website!
sofa cushions
John | July 10th, 2019
Just wanted to say that we were very impressed with the professional service we received from Foam Factory. We ordered 3 custom cut dense sofa cushions and they by far exceeded our expectations. From ordering to delivery we were so impressed with your product. We live in Canada and it took 7 business days to receive our order. It has made our sofa feel new again and we are thrilled with your company and would do business with you again in a heartbeat. Thank you Foam Factory.
New life to my couch
Helen Arano | July 10th, 2019
My couch is just two years old, however I was ready to buy a new one, which cost too much. I bought new cushions and they are better then the originals that came with my couch, gave my couch new life, and safe me a lot of money, since I am on a very fixed income, I cannot express how thankful I am for your fantastic cushions. Thank you Foam Factory!!!!
Deborah J Ireland | July 10th, 2019
Best price on a very good product. I will order from them again. Fast shipping.
Like a new couch
Joyce Luddy | July 10th, 2019
So glad we ordered new cushions, they came promptly, were a perfect cut and its like we have a whole new couch.
Its like having a new couch
Beth | July 11th, 2019
We live on our outdoor sectional during the warmer months and we pretty much had sat out the cushions on it. I'm pretty sure the new foam inserts are even more comfy than the original pottery barn cushions.
Very Satisfied
Awhitman | July 11th, 2019
Ordered new cushion inserts (Lux foam-High Quality with Dacron wrap) and was very happy with what I received. I was nervous about the measuring suggestion to round up AND add 1/2" but the inserts work perfectly, my covers fit snugly with no puckering or wrinkles. Would highly recommend.
Cushion purchaser
Katie W | July 12th, 2019
Very happy with the chair cushions I ordered. Great quality and reasonable pricing.
DIY success
Leonore | July 17th, 2019
I was apprehensive about replacing my foam cushions but after getting a $150 per cushion quote from my interior decorator I figured I’d try it myself. Got the firmest foam with dacron wrap (3 for a little over $100) and voila! Perfect.
Foam Factory
Victor Badescu | July 17th, 2019
Very happy with the product, I will highly recommend this company for all the needs you may have. I am going to buy every time I need .
Retired Guy
Bob Taylor | July 17th, 2019
Very pleased with my two new cushions for my RV sofa. Perfect fit and prompt delivery.
Awesome Serivce
DIY Gal | July 17th, 2019
I have recently competed my second custom cushion protject with high density foam. Great results with custom cut foam. Prompt delivery of exactly what I needed. Great service & prices!