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 tolerance, 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

Eric Milgroom | June 8th, 2021
Just bought 7 seat cushions for my outdoor sofa sectional. I did the measurements but got great help from Haley. I ordered the best firmness and the Dacron wrap. The sofa feels like new. The order was done and shipped pretty quickly and packaged well. So good I am going to order the seat cushion backs.
Customer cut fits perfect!!!
Aaron | May 20th, 2021
I just received my sofa foam inserts. I ordered the HD36 High Quality with dacron wrap and they fit perfectly. Shipping was super fast. Took about week to get to my door. These are more on the firm side for a 6 inch, but that was expected and what I was looking for. Thanks for the fast service and excellent quality.
Renewed our couch!
Rose | March 2nd, 2021
We purchased a couch from Ethan Allen about 11 years ago. The external fabric and construction of the couch is in excellent condition, however, the cushions were just two soft after all this time. I decided to take a chance on “foam by mail“ and can not be happier! I did not tell my husband that I swapped out the old cushions with the new and when he sat down he exclaimed “Wow! This is amazing!” It truly is a brand new couch! I went ahead snd order two more cushions for my wing back chairs that are about 60 yrs old. Can’t wait to get those!! The online order process is simple. The prices are REASONABLE confiding the cost of a new piece of furniture and the results are worth every penny! Customer service was excellent even via email (no phone calls at this time). Thank you for everything!! I will be recommending you to everyone I know!!!
Perfect Replacement
Lin | March 8th, 2021
The down cushions on my couch were so uncomfortable no one wanted to sit on it. The thought of buying a new couch sounded terrible and costly so looked into replacing the cushions instead. The couch is usable again and saved me so much time and money not having to replace the whole thing. Highly recommend that if the fabric is still in good condition that you go this route.
Couldn't be happier
Barbara Erlenbach | February 18th, 2021
Our couch is 18 years old and the cushions were very soft. Ordered 2 replacement cushions, received them in a week. Opened them and let them expand for a day. Put them in the covers and they fit perfectly. You guys are amazing and so reasonable. Just sat down and ordered 2 cushions for our love seat. Thank you. We feel like we just bought a new couch.
Rachael | February 5th, 2021
I got the 6” lux high quality foam to replace the seat of my couch which was 15 years old. It wasn’t easy to replace it, but it was so incredibly worth doing. My couch is now much better than new. I originally thought I might have to replace the springs under the couch, or put in more wood underneath but no, the springs are perfectly fine, they’re just intended to support fresh foam. There was nothing left to support of the old foam. I like a firm couch, this lux high quality foam is perfect. I napped on the couch and it’s more comfortable than my bed. The foam is so firm but it cushions pressure points nicely. I’m really happy with my foam by mail experience. I got a new couch for $90. I’m already planning my next foam purchase!
My Cushion arrived today!
James | December 28th, 2020
I love it! Thanks so much. I had been sleeping on a futon for 5 months. That was horrible! Today I laid down and was on Cloud 9! Thanks again, great craftmanship.
Fabulous cushions
Megan Stevens | January 21st, 2021
I’ve had our furniture for 10 years and it’s in decent shape except for the cushions. They had become super lumpy and uncomfortable. I contacted a lady who does upholstery repair and she wanted to charge me $700 for my cushions!! Might as well by new furniture.. I gave Foam By Mail a shot. I followed all of their measuring directions and my cushions were shipped super fast! I am sitting on my new wonderful cushions and I am in love!!! I have recommended this company to all of my friends and fam!
Donna Rogers | November 25th, 2020
My sofa is 13 yrs old, but being just my husband and I, it's still in great shape, except the cushions needed replaced. I received my new cushions today, and like others say, I feel like I have a new sofa. Thanks so much.
Amazing !
Dean | October 22nd, 2020
You guys are absolutely amazing we had an L-shaped couch and needed five cushions replaced we used the firm foam and it’s amazing feels like we have a brand new couch again. you guys are so affordable compared to a custom upholstery shop. I’m now recommending you to my mom thanks guys for your quality product at an affordable price..
Very happy
Stan | July 3rd, 2020
We are thrilled with our cushion order. Received so quickly and our cushions were perfect!
Great cushions
Gail Stone | July 12th, 2020
The cushions were a perfect match from what I ordered for my chairs. The cushions were more firm than what I wanted, but that was entirely my fault. When I order more cushions, which I will, I'll know what to order next time.
susan tracy | March 13th, 2020
I was very excited when I received my cushions for sofa, chair, and love seat. I waited for 48 hours to let them expand and they fit perfect. Excellent work for custom cut. Will ordrr again from your company when i need them save me MONEY by replacing cushions then going out buying all new set.
Foam for camper table cushions
Timothy O Burlingame | March 18th, 2020
We were very pleased with the product we recieved! Fit was perfect and fimness is exactly what we were looking for! We will definitely be using Foam Factory again when we start replacing our other cushion foam!
I.M von Borstel | March 18th, 2020
My order arrived earlier tham promised and the demensions were perfect.
Great service and product
Maureen | March 18th, 2020
Replacement cushions for our outdoor sofa. I thought we were looking at a new one until these cushions arrived. Completely revived the look and comfort and will give us many more years of use. Appreciate the information on this site on how to measure for the custom size. Fit perfectly.
Terrific product
Anne Spalding | March 18th, 2020
I sit in the same spot on my couch and the cushion was in very poor shape. I ordered a cushion hoping it would work. The price was great, it came in just a few days and looks perfect.
Great Product
Robin Warner | March 19th, 2020
Received our couch for free but the cushions needed replacement. The cushions I ordered arrived quickly and are perfect for my now "new" couch. I would recommend this company again.
Perfect fit.
Marcia Zinser | March 23rd, 2020
We needed a new cushion for a very old chair. We followed the directions, ordered and received quickly. Perfect fit and it looks wonderful!
Nice Upgrade
Bill | May 2nd, 2020
The cushions were a very nice upgrade to the 10 year old cushions that I had. Thank you!
Exactly what I was looking for!
Olivia | May 3rd, 2020
My 6+ year old couch had some loose springs in the cushions, so I ordered a pair of replacement cushions in HD36. Shipped much faster than expected and fit my couch perfectly! Just the right amount of support/cushion for the sofa I use extensively (in a tiny studio apartment, so they get most of the sitting). Would definitely recommend! I also did some research before purchasing and these were a great deal in terms of price and quality.
Kathy | June 3rd, 2020
What a huge difference these cushions have made! My husband is a large man so I ordered extra firm cushions. I feel like I have a new couch!!
Amazing product
Laurie ackroyd | February 28th, 2020
These were exactly perfect. I followed the directions and they fit like a new couch. I would definitely recommend this company.
Claudia | March 4th, 2020
They made ordering the cushion very easy. I measured what I needed and it fit perfectly! The quality was amazing and now I don’t hate my couch anymore. The delivery was also very fast. I will definitely be ordering more cushions!
Great Experience
Pam Jones | March 4th, 2020
The cushions I ordered to replace padding on kitchen and dining room chairs are just what I needed and they arrived pretty quickly.
Couch saver!
Sara | March 4th, 2020
I’ve replaced cushions on two old couches and both times it has made a huge different. Goodbye back pain, hello binge watching.
cushions for couch
Theresa Hebert | March 4th, 2020
I ordered cushions for my couch, the foam was indeed firm which I wanted but on one of the L cushions the edge was not square on one end but cut crooked causing it to slant at an angle.
Lisa | March 4th, 2020
I recently purchased some new sofa cushions and absolutely love the product. I was a bit skeptical that everything would work out, but I followed the measurement instructions on the website and have nice plumb sofas again for a fraction of the cost.
Couch Cushion replacements
Very Satisfied | March 5th, 2020
I bought a great couch about a year ago. Unfortunately the foam cushions that came with the couch did not last as long. Thank goodness I found high density replacements on I simply followed the guidelines for measuring the cushions that the website provided. I got my order more quickly than expected. I opened the packaging to let the foam replacements "breathe" overnight and the next day I removed my old foam cushions from their zip on covers and inserted the replacements. MAN! what a difference! The new foam cushions are an exact fit and high performance density for excellent support. I couldn't be happier with my purchase. Reasonable price saved me from buying an entirely new couch.
Great Stuff"
DG | March 6th, 2020
Great job, folks. 3-in cushion with dacron fits great and looks terrific. You're on my list!
Joe W | March 11th, 2020
Couch cushion replacement for an expensive couch that was 5 yrs old. This replacement was better that the orginal cushion. As a result, I purchased additional cushions to replace all since the rest of the couch was still like new. Very please with purchases.
Great cushion replacement
Shirley Spangler | March 11th, 2020
I ordered dacon wrapped lux foam 5 inch cushions for my vintage sofa and loveseat. What a difference!! It is like having brand new furniture. Cushions are so comfortable. You cannot go wrong by ordering from foam by Fast delivery. Thanks for a quality product!!
New Cushions
Susan Winowiecki | March 11th, 2020
Purchased 2 cushions for a love seat where the cushions had been ruined. The new ones were wrapped in darcon and they fit perfectly. In fact they were better quality than the original ones. Thank you.
Cushion for leather chair
Fred Seid | March 11th, 2020
The cushion fitted properly and the composition of the foam exactly fitted the desired characteristics that was needed. Great job.
Great replacement for old sofa cushions
George M Brennert | March 11th, 2020
Quick shipping and great option for old down filled sofa cushions. Sofa looks brand new and firm again!
Custom Cut Order
Jerry L Bixby | March 11th, 2020
Our complete order was delivered on time and all cuts were exact. So far very happy with the palm for our seats in Travel Trailer so much an improvement on what was provided by Trailer company. Hopefullylly these will last.
SUSAN OLDAKOWSKI | March 11th, 2020
I was looking for replacements for cushions that were 20 years old. I measured but had questions which were quickly answered by customer service, I ordered a set of two and received them quickly. They fit great but when I ordered the second set of two I ordered 1/2 inch smaller for both the length and depth. These also fit well. The dacron covered foam seems to make the two couches like new again. I would definitely recommend this company!
lux cushion
Michael Swenson | March 12th, 2020
the high quality foam is what should be in all big and tall office furniture. so comfortable and supportive.
Great service
Jie | March 12th, 2020
normally I buy the replacements for cushions from local store. This year I decided to order on-line. The whole process takes less a week to get the my new cushions it is cheaper than the local store even Including the shipping charge and tax and with the better quality i like this company, strongly recommend!!!
Excellent Product
Jacqueline Smerdel | February 15th, 2020
I ordered the high quality Lux Foam with dacron wrap for my couch and love-seat. The product was extremely high quality! The cushions have kept their firmness and shape and they have completely revived out couches! Additionally, the dacron wrap covered the whole cushion! Excellent quality! It feels like we got new furniture except it is even more comfortable than when we bought it! I would absolutely order from them again!
Replacement couch cushions
Vincent M GIGLIO | February 19th, 2020
We have an indoor/outdoor wicker couch that was in great shape with the exception of the cushions. I purchased 3 replacement foam cushions with the Dacron coating. After watching a Youtube video on how to insert the foam, the couch now looks brand new. The measuring instructions were very simple and the delivery of the foam was relatively quick. I am happy with the results and would recommend the Foam Factory to anyone before getting rid of your old couch or chair.
Kathleen Young | February 19th, 2020
I ordered one T-cushion Lux Foam to replace a very old cushion for a chair. I wasn't sure if I measured or chose the right foam correctly but it was perfect! I immediately ordered a second one. Thank you!
Maya | February 19th, 2020
Very reasonable price, and high quality. It's honestly more comfortable than my couch. Really quick turn around time too! I will be shopping here again.
So far so good
Lisa | February 19th, 2020
We ordered 3 foam cushions covered in dacron to replace our couch cushions. They arrived in perfect condition with good firmness. It is too soon to give a review as to their longevity of firmness as we have only had them for a couple weeks. We are hoping to get several years out of these new foam cushions. Fingers are crossed!!
HQ Lux Foam
Hans | February 21st, 2020
Purchased High Quality Lux Foam for Vintage trailer Dinette. Couldn't be happier, very comfortable and nearly half the cost I usually pay as well as free shipping. I rebuild one vintage trailer per year for hobby. I ordered another small piece and it was delivered in less than a week. Great service!!!
RV Dinette Cushion Upgrade
Mark Thomas | February 22nd, 2020
Replaced our OEM dinette seat cushion foam with the High Quality Lux Foam (4 inch). Diference is night and day. Now it is very comfortable sitting at the dinette without feeling the plywood beneath.
HD36 custom cut for a dog bed
James Martin | February 23rd, 2020
I have two large 34x48x6 dog beds. The covers are still in great condition, but the padding has been wearing down. Since new beds of that size with memory foam are expensive, I ordered once piece of HD36 foam custom cut to the bed size to try it out. The foam was less than the price of a new dog bed, and fit into my cover perfectly. At 6" high, it was too firm, and my dog didn't like it. I cut the foam in half to use 3" of foam and added 3" of polyester fiber fill on top, and now it's the most comfortable bed ever!
Great couch upgrade!
Nancy | February 26th, 2020
I bought a couch on sale from Wayfair that looks great but the cushions flattened like pancakes when anyone sat on them. High-density replacement foam from the Foam Factory made this inexpensive couch look and feel like a couch that costs three times what I paid. The cushions came quickly, just as ordered, and were packaged well. It takes some strength to get the foam into the covers but you won't regret it. So comfortable!
Kathleen Young | February 26th, 2020
After a successful first purchase of a chair cushion, I quickly ordered a second and it was just as fine! Thank you!
Replacement cushions for couch
Karen A Powell | February 26th, 2020
This is our second time ordering seat cushions for our couch. We got the first set about 6-7 years ago. Very happy with the cushions, the company, the price,and the shipping