Cushion sizes
Custom Cushion Report 2026: Sizes, Foam and Fabrics Our Customers Choose
Twelve months of real Fabrica Kraft orders: the fabric, foam, thickness and sizes customers chose, the states ordering most, and what it means if you are ordering your own cushions.
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The short version: across 12 months of Fabrica Kraft orders (November 2025 to October 2026), Sunbrella was the fabric named in about 7 in 10 cushion and cover orders, quick-dry foam made up about 7 in 10 custom-cut foam pieces, 4 inches was the median cushion thickness, and California, Florida, Texas and New York sent the most orders. Below is what our customers actually chose, and what it means if you are ordering your own.
How we got these numbers
We looked at every order placed on fabricakraft.com between November 1, 2025 and October 31, 2026, leaving out cancelled and test orders. All figures are shares of those orders, not survey answers or estimates. Where a finding rests on a smaller group of orders (for example, only orders that recorded exact foam and size details), we say so. We do not publish order counts or customer details.
1. Where custom cushion orders come from
More than 95% of orders shipped within the United States, to 43 states and Washington, DC. Five states sent close to half of all US orders.
| State | Share of US orders |
|---|---|
| California | 19% |
| Florida | 12% |
| Texas | 7% |
| New York | 7% |
| Pennsylvania | 4% |
California and Florida both have long outdoor seasons, which fits the next finding: most of what people order is meant to live outside.
2. Sunbrella is the default fabric
Sunbrella was named in about 7 in 10 cushion and cover orders over the year. In the orders that recorded every fabric choice in detail (October 2026), Sunbrella made up 85% of cushion units. The rest were mostly Warwick fabrics, including faux leather and velvet for indoor seating.
The reason is simple: Sunbrella is a solution-dyed acrylic, so the color goes all the way through the fiber and resists fading in sun. It is water-repellent rather than waterproof, which is why the foam choice below matters just as much. You can order Sunbrella swatches or build a Sunbrella cushion to your exact size.
3. Quick-dry foam wins for outdoor cushions
Of the custom-cut foam pieces ordered over the year, about 7 in 10 were Dry Fast (quick-dry) foam. Standard high-density foam, fiber fill and softer foams made up the rest.
| Fill type (custom-cut foam pieces) | Share of pieces |
|---|---|
| Dry Fast (quick-dry) foam | 70% |
| Fiber fill | 17% |
| High-density foam | 9% |
| Luxury and super soft foams | 5% |
Dry Fast foam has an open cell structure, so water drains through it instead of sitting inside the cushion. If your cushions stay outside, this is the fill most of our customers pick. See custom-cut foam for every option.
4. 4 inches is the most common thickness
The median thickness was 4 inches, both for custom-cut foam and for complete cushions. For foam pieces, 4 inches and 5 inches were the two most ordered thicknesses, followed by 3 inches and 6 inches. In the orders that recorded full cushion details (October 2026), deep seat and sofa cushions ran thicker (mostly 5 to 6 inches), while chair and bench pads ran thinner (most often 3 inches).
Not sure which thickness you need? Our cushion thickness and foam guide walks through it by seat type.
5. Square cushions lead, but most sizes are one-offs
About a third of custom-cut foam pieces were square, and 27 × 27 inches and 24 × 24 inches were the sizes ordered most often. Beyond those, very few exact sizes repeated. That is the real story of custom cushions: most furniture does not match a standard size, which is why people order to measure in the first place.
6. Spring is the busy season
Orders build from March and peak in April and May as people get patios ready. December and January were the quietest months of the year, and October 2026 was the single busiest month. If you want cushions in place for the start of outdoor season, ordering in March or early April avoids the spring rush.
7. About 1 in 8 orders is for fabric swatches
About 12% of all orders were for fabric swatches only. Seeing and feeling a color in your own light before committing is a common first step, especially with neutrals that can read warmer or cooler than they look on screen.
What this means if you are ordering
- Outdoors: Sunbrella fabric and Dry Fast foam are the fabric and the foam most customers choose.
- Thickness: 4 inches is the middle ground; go thicker for deep seats and sofas, thinner for dining chairs and benches.
- Size: measure your own seat rather than relying on a standard size. Most orders we see are unique.
- Color: order swatches first if you are choosing between close shades.
Frequently asked questions
What is the most popular fabric for custom outdoor cushions?
In our 12 months of orders, Sunbrella was named in about 7 in 10 cushion and cover orders, making it the most chosen fabric by a wide margin.
What foam do most people choose for outdoor cushions?
About 7 in 10 custom-cut foam pieces we sold were Dry Fast (quick-dry) foam, which lets water drain through instead of staying in the cushion.
How thick should a custom cushion be?
The median thickness in our orders was 4 inches. In orders with full cushion details, deep seat and sofa cushions were mostly 5 to 6 inches, and chair and bench pads were most often 3 inches.
Where does this data come from?
From every order placed on fabricakraft.com between November 1, 2025 and October 31, 2026, excluding cancelled and test orders. We will update this report as new orders come in.
