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

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.
the best!
Michael E | December 5th, 2019
Foam Factory helped me transform my uncomfortable beat up couch to like new! Customer service is excellent! When I ordered the wrong foam for a seat back, I was immediately contacted and given the right recommendation. Super company!
New Life to Old Couch
Melissa P | December 5th, 2019
Every time you sat on our couch, you'd sink in and slide out--after 7 years, the cushions had had it. But the rest of the couch was fine, so I couldn't justify replacing the entire thing (and spending thousands). That's when I discovered Foam Factory. I could replace all three troublesome seat cushions for a fraction of the price of a new couch. The ordering process was simple--a customer service rep contacted me concerned about the cushion quality I initially ordered. They suggested a different density level, which in the end saved me money! The cushions were shipped quickly--and now, it's like I have an all new couch. I highly recommend Foam Factory.
Inexpensive solution for old chairs
Catherine Vaughan | November 8th, 2019
I have two old arts and crafts armchairs I picked up at fleamarkets. The upholstery andthe cushions were totally gone. An upholsterer said it would cost $250 each to replace the seats. With a screwdriver and a hammer and some pillow shams I bought on Amazon I now have two very comfy beautiful chairs.
best company on the internet
mk | November 8th, 2019
My favorite company existing. Incredible variety of products, ample customization. Order accuracy and customer support unmatched. I Love you foam by mail.
Great stuff
Aaron G Brindell | November 11th, 2019
I've ordered a few different things now, and they have always been great quality, and delivered fast. I won't go anywhere else for my foam needs in the future.
Gail Goldman | November 12th, 2019
Having never used this site before, I was a little cautious but easy to order, good prices and custom size would be ideal. Ordered piece for my new bench seat in mud room which friend will sew. They called me to make sure I’d ordered the right foam and how nice of them! Proceeded with order and it’s perfect. Friend is making the cushion and I can’t wait! Glad I found this site!
Wonderful experience and product!
John Geis | November 12th, 2019
I knew nothing about cushions, so I followed the measuring instructions exactly and read the foam descriptions carefully. The cushions arrived quickly and I was thrilled that they fit the covers exactly. I didn’t realize quite how bad the old ones had gotten until I sat on the new ones and I could no longer feel the frame of the foldaway bed. Great products, good price – I could not be happier. I’ve bookmarked these folks, so when I next needs cushions, I back.
Couch Cushion inserts
DMR | November 13th, 2019
What great service and quality! I cannot begin to explain how much new foam cushions made my worn out coach more comfortable and attractive again! Thank you!
Couch cushions
Nancy | November 13th, 2019
Perfect fit. Great price. Easy directions on measuring for new cushions.
Very pleased with couch cushions
Rita Scott | November 15th, 2019
Ordered according to size chart. They fit perfectly and are the firmness I ordered. Didn’t expect it to fit but it did and I am happy!
Great cushions
Lou | November 20th, 2019
I ordered cushions for my 30 year old lazy boy sofa sleeper. They fit perfect and it feels like brand new again.
Great transaction
Cindy | November 20th, 2019
Ordered foam for a bench seat I was making. Measured as instructed. Order arrived in timely manner and fit perfectly. Best price I saw anywhere. Quality foam. No complaints.
Kenley | November 20th, 2019
I ordered a few 2 inch cushions for a bench we built in our kitchen. They turned out absolutely perfect and were so comfortable. It was so convenient to have them cut to size already. I will definitely use this company again for my next project.
seat cushions
joy j | October 16th, 2019
super fast delivery....great product. the cushions fit perfectly, and made my re-upholstering project go so quickly!
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.