Custom Outdoor Cushion Covers - Sunbrella

Custom outdoor cushion covers for the foam you already have. If your cushions still hold their shape but the fabric has faded, torn or gone moldy, a new zippered cover is the simplest fix. We sew each cover to the exact size of your foam in Sunbrella fabric, for patio chairs, sofas and sectionals, chaise lounges, benches, swings and daybeds.

How to measure

• Take the old cover off and measure the foam itself: width, depth and thickness.
• Measure each cushion separately; cushions that look the same often differ by an inch.
• For tapered or shaped cushions, give the front and back widths, or trace the foam on paper and send a photo.
• Note where you want the zipper (usually the back edge) and whether you want piping or ties.

Fabric

Pick from 41 popular Sunbrella colors above. Want a different color? We stock over 160 Sunbrella fabrics: browse the full range and name it in your quote notes.

Foam and fill options

All foam is made in the USA and covered by a 3-year warranty.

• High Density foam: medium feel for everyday seating. 2.8 lb/ft³ density, 35 lb ILD, about 16-year life.
• Luxury foam: firm, best for dining seats 1″ to 3″ thick. 2.8 lb/ft³, 50 lb ILD, about 16-year life.
• Dry Fast foam: open-cell foam that drains water, best for outdoor and marine use. 1.8 lb/ft³, 60 lb ILD, 5–8 year life.
• Super Soft foam: for back cushions only. 1.2 lb/ft³, 12 lb ILD.
• Dacron wrap: a 1″ polyester fiber layer around the foam for a fuller, rounded look. Do not reduce your measurements for it.
• Fiber fill: soft polyester fill for loose back cushions.

How to order

1. Choose your fabric above, then click Start Your Custom Order.
2. Enter your measurements in inches (rounded up to the nearest 1/4″), foam, thickness, piping and ties in the notes.
3. We confirm the price and specs by email before we cut anything.

Foam up to 6″ is one solid piece; 6″ to 8″ is two pieces bonded at no extra charge. For thicker or layered cushions, contact us. Tolerance is ±1″ on length and width and ±1/2″ on thickness. Ships in about 2 weeks for in-stock fabrics, 4 weeks otherwise, with free shipping.

Questions

Do I measure the foam or the old cover?

Measure the foam. Old covers stretch and shrink, so the foam gives a truer size. We size the new cover for a snug fit.

Can I buy new foam too?

Yes. If your foam has gone flat, order a full cushion instead, or add Dry Fast or High Density foam in your quote notes.

Do the covers have zippers?

Yes. Every cover has a zipper so you can remove it for cleaning.

Can you match my existing piping or ties?

Yes. Tell us the style in your quote notes and send a photo of the old cover.