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 custom cushion 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 seating cushions.

With our selection of couch cushions replacements and custom cushions, find the perfect shape for your needs at an affordable price. When a sofa has old, flattened cushions, it can make the seating less supportive and comfortable. Most cushions tend to lose their appeal over time and become relatively 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 custom cushion options.

Have an unusual furniture set? It’s easy to get the customized seating you need! Contact Us and we can help you get started!

Foam meets CertiPUR-US® certification.
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.

Frequently Asked Questions

How do I order custom cushions?

To order a custom cushion, start here on our Couch Cushion Replacements and Custom Cushions page. Next, choose a shape that best fits the furniture’s original cushion. Click on the shape, and you’ll be taken to the shape’s page. You can enter the size and thickness you need on that web page and then click on the next step. If you are unsure how to measure, we also have a convenient and easy-to-follow PDF guide on How To Measure.

Who makes custom cushions?

Custom cushions are made right here at Foam Factory, Inc. headquarters in Southeast Michigan. They are cut with a wide range of today’s most innovative technology.

How thick should a bench cushion be?

There is no standard thickness for cushions. Typically, the thickness you want to go with would be in accordance with the cover for the couch or bench cushion.

Write a Review

Great Replacement Foam
Joe | May 26th, 2022
I purchased four Left/Right Window Seat foam as replacement fir my odd shaped couch cushions. The detailed measurement instructions were easy to follow and accurate. The product arrived quicker than expected and fitted perfectly. I ordered the firmest support foam and they are perfect for my use.
Excellent product
Joanne | May 26th, 2022
I ordered the dacron wrapped foam for window seats. It worked perfectly, and the seats are very comfortable. The cushions are the exact size I ordered and they shipped in the timeframe promised. Thank you so much!
Good Product
fjb | May 19th, 2022
Pleased with our 3 sofa cushions Good friendly service
Couch Cushions
Tom | May 9th, 2022
I ordered 4 couch cushions HD36 Foam High Quality and right from the ordering page to delivery the service was the very best and the cushions make my 12 year old couches feel brand new!! Wish I had of done this a couple years ago! Thank you Foam Factory!!
Perfect fit
Mike M | May 3rd, 2022
Ordered custom cut round Lux foam for replacing old seating for bar stools. Sizing was exact, quality is excellent and they fit perfectly.
Couch cushions
Kathy | May 3rd, 2022
We ordered the Lux Foam High Quality. Our couch was almost unusable and now it gives us the support we need again. It is very firm, even a little firmer than we'd like but hopefully they will soften over time.
Great Job!
Carol | April 23rd, 2022
Ordered 8 pieces to replace foam inserts in my screen room furniture. Easy to order, shipped very quickly. Quality work with the Dacron wrapping and perfect fit. These made my furniture comfortable again! Great job!
Overall very Good Experience
Robin Long | March 30th, 2022
Ordered a replacement custom T Cushion with Dacron Wrap for a wing chair. I was very hesitant to order a custom cushion but the cushion arrived in the EXACT size I requested. The quality of the 4" foam looks great. It's too early to tell the durability of it as we have only had it for a couple weeks but so far it is extremely comfortable. Prices were good and shipping charges were reasonable. Delivery was extremely quick as well. All in all we are very happy our experience.
2" x 15" x 36" with the dacron covering
jan | March 29th, 2022
Delivery was very quick. I was surprised it was 2 pcs of foam glued together to form the 15" width. Hope it stays secure. Also the dacron material was great but they stapled it along the 2" side so bumpy when I put my covering on it. I removed it and wrapped it so the joint was on the underside on my cushion . Would depend what you are using it for but would be a note for the company to perhaps ask that. All and all, happy with this and the cushion looks great.