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Custom Cushion Foam, Cut to Size

Foam cushion inserts cut to your exact size: Dry Fast foam for outdoor and marine use, and high-density foam for sofas, window seats and boat seating.

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About this collection

Custom cut foam and cushion inserts, cut to your exact size and shape for indoor and outdoor cushions, mattresses, benches and boats. Choose Dry Fast quick-dry foam for anything that gets wet, High Density for everyday seats, Luxury for firm dining seats, or Super Soft for back cushions. All foam is made in the USA and cut to within ±0.5″ of your measurements.

Which foam should I choose?

Foam Feel Best for Density / ILD Typical life
Dry Fast Medium-firm Outdoor, pool and boat cushions 1.8 lb/ft³ / 60 lb 5–8 years
High Density Medium Sofa seats, chairs, mattresses 2.8 lb/ft³ / 35 lb About 16 years
Luxury Firm Dining seats 1″–3″, benches 2.8 lb/ft³ / 50 lb About 16 years
Super Soft Soft Back cushions and toppers only 1.2 lb/ft³ / 12 lb About 5 years

Questions about custom foam

What is Dry Fast foam?

Dry Fast is a reticulated, open-cell foam. Water drains straight through it and air dries it quickly, so it is the standard choice for outdoor, pool and marine cushions.

What is the best foam for outdoor cushions?

Dry Fast foam. Standard foam soaks up rain and stays wet, which leads to mildew and flattening. Dry Fast drains in minutes.

How thick can you cut foam?

Up to 6″ is one solid piece. From 6″ to 8″ we bond two pieces at no extra charge. For thicker or layered foam, contact us for a quote.

Do I measure the foam or the cover?

Measure the old foam edge to edge, or the inside of the cover if the foam is missing. Do not reduce the size for a Dacron wrap: the wrap fills the cover for a snug fit.

What is Dacron wrap?

A 1″ layer of polyester fiber wrapped around the foam for a fuller, rounded look. It is an option, not something you remove.

Can I order foam without a cover?

Yes. Everything in this collection is foam or fill only. For a complete cushion, use a cushion builder; for covers only, order cushion covers.

Custom Cut Dry Fast Foam

If the foam inside your cushions has flattened, sagged, or turned crumbly, the cushions have reached their replacement point, not the covers. Custom foam cushion inserts cut to size restore the seats without starting over.

Uncovered patios, pool decks, and any outdoor setting where cushions regularly get exposed to rain need Dryfast foam. This open-cell reticulated foam drains within hours rather than trapping moisture that could eventually lead to mold growth. The same drainage-first construction applies to marine foam used for boat seats, helm cushions, cockpit pads, and cabin berths. For indoor applications such as sofas, window seats, and banquettes, as well as covered outdoor furniture, custom cushions made from high-density foam deliver the right level of firmness for seat cushions, while back cushions are better suited to a softer foam grade. Ask our business team for the right foam grade. 

Each cushion foam piece is cut to your exact seat depth, width, thickness, and corners. Non-rectangular shapes such as trapezoid window seats, L-shaped sectionals, and curved boat seats can be quoted from a simple sketch. Any Outdoor cushion foam replacement follows the same ordering process. Send your dimensions, and our production & design team will recommend the right density and grade.

FAQs for Custom Foam Inserts for Outdoor and Indoor Cushions

Quick answers about sizing, fabrics, foam and delivery.

What is the difference between Dryfast foam and standard polyfoam? + −

Dryfast is an open-cell reticulated foam that allows water to pass through and out of the cushion. In contrast, standard polyfoam is closed-cell and retains moisture. If kept uncovered outside, in spaces such as on a boat or near a pool, Dryfast is the correct specification. Standard polyfoam is better for indoor sofas, window seats, and fully covered outdoor furniture.

Can I order foam cut to my exact cushion dimensions? + −

Yes. Every custom foam inserts on FabricaKraft are cut to the seat depth, seat width, and thickness you provide. Non-rectangular shapes such as trapezoid window seats, L-shaped sofa seats, and curved boat berths are quoted on request with a simple sketch.

How long does outdoor foam last? + −

Outdoor cushion foam usually lasts for years, depending on use and conditions. Their lifespan can be extended if kept covered or properly stored. Cheap big-box foam often collapses before the season ends, when customers decide to replace the existing inserts.

What foam density should I order for a sofa cushion? + −

For sofa seat cushions, high-density polyfoam provides the right balance of firmness and softness. Lower-density compresses quickly and loses shape within a year. For back cushions, a softer foam works better. If you are not sure, send us your use case, and we will recommend the right density.

Is the foam fire-retardant and CertiPUR-US certified? + −

Our high-density polyfoam options are available in CertiPUR-US certified versions, which means the foam has been independently tested for low VOC emissions and is made without ozone depleters, formaldehyde, or heavy metals. Fire-retardant variants are available for commercial seating projects that require compliance documentation.

Still have questions?

Our team is here to help with specifications, custom requests, lead times, and project guidance.

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