Custom Cut Foam for Cushions

When your cushion covers still look good but the seats have gone flat, new foam for couch cushions brings them back. We cut replacement foam for sofa cushions, chair pads, benches, window seats and boats to the size you send. Typical seat thickness is 3–5 inch, and the builder goes up to 8 inch. For thicker foam, email operation@fabricakraft.com for a quote.

Looking for upholstery foam or a high density foam sheet? Every rectangle we cut is a foam sheet made to your length, width and thickness, from thin dining-seat pads to sofa seats up to 8 inch. HD36-R and Lux-R are both high density foams; they differ in firmness. Dryfast is our open-cell outdoor foam, and Super Soft is for back cushions only.

Custom foam cut to any size and shape

Every piece of custom foam is cut to order from CertiPUR-US certified foam. Pick the shape and the foam, enter your size, and we cut it.

• Rectangle and square foam for sofa seats, benches and window seats
• Trapezoid foam for tapered dining and patio chair seats
• Round foam for stools, bistro chairs and egg chairs
• Dry Fast foam for patio, pool and boat cushions
• Custom foam mattresses for RVs, boats, daybeds and odd-sized beds
• Super Soft foam for back cushions and fiber fill inserts for pillows

Which cushion foam should I choose?

An optional Dacron wrap adds about 1 inch and gives a softer, rounder look. Our cushion size and foam guide explains each option.

About 7 in 10 custom-cut foam pieces we sold over the past year were Dry Fast foam, and 4 inches was the median thickness. See the full Custom Cushion Report 2026.

Foam density and ILD, explained

Density (pounds per cubic foot) tells you how long foam lasts: higher density keeps its shape for longer. ILD (indentation load deflection) tells you how firm it feels: the number of pounds it takes to press the foam down by 25%. A lower ILD feels softer, a higher ILD feels firmer. The two are independent, which is why our HD36-R and Lux-R share the same 1.8 lb density but feel different.

• 12–20 ILD: soft and squashy. Back cushions and pillows only; it bottoms out under a seated person.
• 30–40 ILD: medium. The comfortable range for most sofa and lounge seats.
• 45–60 ILD: firm. Dining chairs, thin pads, benches and outdoor foam.

Which foam feels most like an indoor couch?

For the softest seat that still holds up to everyday use, choose HD36-R with a Dacron wrap. At 35 ILD it is the softest foam we recommend for seats, and the wrap softens the top layer and rounds the edges so the cushion fills its cover like original sofa cushions. Pair it with Super Soft backs for a relaxed, sink-in sofa feel. We don't offer a seat foam below 35 ILD, because softer foams flatten quickly when sat on every day.

For a covered or screened porch, HD36-R with Sunbrella covers is usually the most comfortable choice. Choose Dryfast only where cushions get rained on, as it is firmer.

Couch cushion foam

For indoor sofa seats, HD36-R gives a medium, supportive feel and Lux-R gives firm, even support. Order couch cushion foam cut to size, or see complete replacement couch cushions if the covers are worn too. Not sure which to replace? Read replace the foam or the whole cushion.

Outdoor foam

Standard foam soaks up rain and stays wet. Dryfast outdoor foam is reticulated, so water drains straight through, and it is antimicrobial. It is the right choice for patio, pool and boat cushions. Pair it with Sunbrella cushion covers.

Custom foam mattress

RV bunks, boat V-berths, daybeds and antique frames rarely take a standard mattress. We cut a custom foam mattress to your exact size, including angled and rounded corners, up to 8 inch thick.

How to measure

Measure the old foam edge to edge, or the inside of the cover if the foam is missing. See our measuring guide. Foam cut to order can't be swapped after delivery, so please check your sizes before you approve the spec sheet. Not sure about firmness? Order one piece first and try it before ordering the full set.

Questions about cushion foam

What is your softest foam for seat cushions?

HD36-R at 35 ILD and 1.8 lb density. Add a Dacron wrap for a softer top and rounder edge. Super Soft (12 ILD) is softer but is made for back cushions only.

Can I buy foam to fit covers I already have?

Yes. Measure the inside of your cover seam to seam and order foam to that size. With a Dacron wrap, we allow for the extra 1 inch so the insert fills the cover without straining the zipper.

Can you cut custom foam to any shape?

Yes. Rectangles, trapezoids and circles are in the builder. For L-shapes, curves and V-berths, send a paper template and we cut the foam to match.

How thick can you cut foam?

Up to 6 inch from one solid piece, and up to 8 inch by bonding two layers. For anything thicker, email operation@fabricakraft.com for a quote.

Can I buy foam without a cover?

Yes. Every foam on this page is sold on its own. If you need covers too, see custom cushion covers or complete custom cushions. Selling cushions under your own brand? See our white-label cushion program.

What warranty does the foam have?

It depends on the foam: HD36-R and Lux-R 7 years, Dryfast 5 years, Super Soft 3 years and poly foam 1 year. Our workmanship is covered for 2 years.

How fast will my foam arrive?

Most orders are made and dispatched in 2–3 weeks, with free standard shipping. Vacuum-packed foam regains its full shape within 12–18 hours of unpacking.