DIY Chair Cushions

Categories: Utility, Decor, Featured

Basic DIY chair cushions are pretty easy to make. This project uses two different thicknesses of foam for a custom look. Once the foam cushion is cut out, then it is used to make the pattern for the cover. The basic style of these covers is clean with a straight edge — nothing fancy: no piping or zippers included. Just cut, stitch and go!

What you need to make this project

1" and 3" thick pieces of Foamology® Project Foam to fill the desired space or cushion size
Denim fabric -- purchase adequate to cover cushions with seam allowance (project shown here used 1-1/2 yards of 54" wide denim)
Electric Knife (to cut foam)
Pencil or Marker

Quick Shop


  • Top Cushion Tested for Fit

Step One

Plan it Out

First things first, decide on how you want your cushion to look. In this example, we chose 3 inch thick foam for the bottom cushion so that there was lots of comfort. We went with only a 1 inch thick foam for the back cushion as this seemed right for adding a bit of softness and to not overwhelm the chair. Here is what the DIY chair cushions looked like prior to being used as patterns (and chair is not painted yet!)

  • Both Cushions Cut

Step Two

Measure and Cut

We wanted the foam cushions to mimic the line of the wicker chair. The bottom cushion was shaped at the back whereas the back cushion was cut to match the curved line of the chair. Use a soft pencil or a marker to indicate cutting lines on the foam surface.

Use an electric knife to cut along the marker lines. Work at keeping the blades of the electric knife straight and perpendicular to the foam. Take care not to angle the blade as this will result in an uneven, angled cut. cutting in a straight even  line.   Work at cutting larger and testing fit as you go. The reason to do “less is more” is obvious — you can always trim to fit but not the other way around.

  • Use Foam to Make Pattern

Step Three

Cut Out Denim Pieces

Once you have your foam pieces cut to size then use them as your pattern. Place each on the wrong side of your fabric and use a soft pencil or marker to make an outline around your foam pieces. Cut out two pieces for each, allowing at least a 1/2 inch seam allowance.

You will also need to cut out the side piece which is basically just a long strip — it will be joined in the back or at the corners. Measure around the outside of your foam cushion to figure out the length of the side strip needed (adding seam allowance). Figure out the side strip width by adding at least a 1/2 inch seam allowance for BOTH sides (example: 1 inch thick side, cut a 2 inch wide strip — 3 inch thick side, cut a 4 inch wide strip).

  • Side Strip Pinned in Place

Step Four

Stitch up Covers

Once you have your pieces all cut out, pin the side strip to the top and bottom covers with right sides together. Line up center points of side strip with center point of bottom and top covers to keep fabric aligned. Final step is to stitch up all seams, leaving a large opening at the back for inserting the cushion.

Once stitched, trim all seams and cut across corners to reduce bulk. Turn cover to outside and press carefully. Insert foam through opening. Once foam cushion is well seated inside cover, use a needle and thread to stitch opening closed.