Make durable, stylish outdoor cushions yourself! This guide shows beginners how to choose fabrics, select foam, measure, cut, sew, and finish weather-resistant cushions that will brighten your patio and last for seasons to come.
Is your outdoor furniture looking a little bare or tired? Adding your own custom cushions can transform your patio, balcony, or garden into a cozy oasis. Buying ready-made cushions can be expensive, and sometimes you just can’t find the perfect color or size. But guess what? Making your own is totally doable, even if you’re new to sewing! We’ll walk you through everything you need to know, step-by-step, so you can create beautiful, long-lasting cushions that perfectly suit your style and your space.
Why Make Your Own Outdoor Cushions?
Creating your own outdoor cushions offers a wonderful blend of creativity, cost-savings, and personalization. Let’s explore why this DIY project is so rewarding.
- Customization: You get to pick the exact fabric, color, pattern, and size to match your decor and furniture perfectly.
- Cost-Effectiveness: DIY cushions are often significantly cheaper than buying commercial ones of similar quality.
- Durability: By choosing the right materials, you can create cushions that are more durable and weather-resistant than many store-bought options.
- Satisfaction: There’s a special kind of pride that comes from lounging on furniture adorned with something you made with your own hands!
- Eco-Friendly Potential: You can choose sustainable fabrics and repurpose materials for a greener approach.
Gathering Your Supplies: What You’ll Need
Before we dive into the fun part – sewing! – it’s crucial to have all your materials and tools ready. This makes the process much smoother and more enjoyable.
Essential Materials
- Outdoor Fabric: Look for fabrics specifically designed for outdoor use. These are treated to resist UV rays, mildew, and water. Polyester, acrylic, and specially treated cotton blends are great choices. For inspiration and a wide selection, check out reputable fabric stores or online retailers specializing in home decor.
- Cushion Foam: You’ll need foam that’s firm enough to provide support but comfortable. Outdoor foam is often treated to be more resistant to moisture and mildew. You can buy foam by the yard or in pre-cut sizes. For density and firmness, aim for high-density polyurethane foam.
- Thread: Use heavy-duty polyester or nylon thread. This type of thread is strong and resistant to UV damage and moisture, ensuring your seams won’t break down.
- Closures: Options include zippers, Velcro, or ties. Zippers offer a neat, enclosed look, while Velcro is easy to attach and remove. Ties are great for securing cushions to furniture.
- Optional: Piping/Cording: For a more finished, professional look, you can add piping around the edges. You’ll need piping cord and fabric strips to create it.
Tools You’ll Need
- Sewing Machine: A sturdy sewing machine is recommended, especially for thicker outdoor fabrics.
- Fabric Scissors: Sharp scissors are essential for clean, accurate cuts.
- Measuring Tape: For accurate measurements of your furniture and foam.
- Fabric Marker or Chalk: To mark cutting lines.
- Pins: To hold fabric pieces together.
- Needles: Use a denim or heavy-duty needle for your sewing machine.
- Rulers or Straight Edge: To assist with cutting straight lines.
- Optional: Rotary Cutter and Mat: These tools can make cutting fabric even faster and more precise.
Planning Your Cushions: Measurements and Design
Proper planning is key to a successful DIY project. Let’s get those measurements just right!
Measuring Your Furniture
The first step is to accurately measure the dimensions of the furniture piece where the cushion will sit. Measure:
- Length: The longest side.
- Width: The shorter side.
- Height/Depth: How thick you want your cushion to be.
Tip: Measure each individual seat or back if they are separate pieces. For curved furniture, you might need to use a flexible measuring tape or even a piece of string to get accurate lengths.
Determining Cushion Dimensions
Once you have your furniture measurements, you need to decide on your cushion’s final size. Consider these points:
- Seating Comfort: Do you want the cushion to fit flush with the edges of the furniture, or do you prefer a slight overhang? For a snug fit, add a small amount (e.g., 1/2 inch) to the length and width.
- Foam Thickness: This determines the height of your cushion. Standard chair cushions are often 3-4 inches thick, while deeper seat cushions might be 5-6 inches.
- Seam Allowance: You’ll need to add extra fabric for sewing the cushion cover. A standard seam allowance is 1/2 inch to 1 inch. For outdoor fabrics, 1/2 inch is often sufficient and helps create a less bulky seam.
Example Calculation:
Let’s say your furniture seat is 20 inches wide by 20 inches deep, and you want a cushion that’s 4 inches thick.
- Cushion Fabric Width: (Furniture Width + 1/2 inch overhang) x 2 + (Foam Depth x 2) + (Seam Allowance x 2) = (20 + 0.5) x 2 + (4 x 2) + (0.5 x 2) = 41 + 8 + 1 = 50 inches.
- Cushion Fabric Length: (Furniture Length + 1/2 inch overhang) + (Seam Allowance x 2) = (20 + 0.5) + (0.5 x 2) = 20.5 + 1 = 21.5 inches.
- So, you’d need a piece of fabric that is approximately 50 inches by 21.5 inches.
Note: This calculation assumes a simple rectangular cushion. For more complex shapes, you may need to create a paper pattern first.
Designing Your Cushion Cover
Most outdoor cushions are made with a simple envelope closure or a zipper. For beginners, an envelope closure is often the easiest.
- Envelope Closure: This involves overlapping fabric at the back, creating a simple flap that the cushion insert slides into. It requires no hardware like zippers.
- Zipper Closure: This provides a very clean, professional finish, but requires more precise sewing.
- Ties: If you want to secure your cushions, add fabric ties to the sides or back of the cover.
Step-by-Step: Making Your Outdoor Cushions
Ready to start creating? Follow these simple steps for beautiful, durable outdoor cushions.
Step 1: Cut Your Fabric
Using your measurements and calculations, carefully lay out your outdoor fabric. Use your fabric marker or chalk to draw the cutting lines. It’s always a good idea to add an extra inch to your measurements for a generous seam allowance, especially if you’re a beginner. Cut out all the required pieces.
For a basic rectangular cushion, you’ll typically need:
- One piece for the bottom.
- Two pieces for the sides (if your cushion is very deep and you want to avoid bulky corners).
- One piece that will form the top and the flap for an envelope closure (this large piece is folded in half).
Alternative: For simpler cushions, you can cut two identical pieces (one for the top, one for the bottom) and then sew strips of fabric around the edges for the depth. This is often easier for beginners.
Step 2: Prepare the Envelope Closure (If Using)
If you’re making an envelope closure, take the large top piece. Fold one of the long edges over by 1/2 inch, then fold it over again by another 1/2 inch to create a clean hem. Stitch this hem down securely. Do the same for the other long edge of this piece. This hemmed edge will be the opening for your cushion insert.
Step 3: Sew the Cushion Cover
Now for the sewing!
Method A: Simple Two-Piece Cushion (Top & Bottom)
- Place the top and bottom fabric pieces right sides together.
- If adding ties, position them now between the layers along the raw edges where they are to be sewn, ensuring the tie loops face inward.
- Pin all around the edges, leaving one side open for turning and inserting the foam.
- Sew around three sides with your chosen seam allowance (e.g., 1/2 inch), backstitching at the beginning and end.
- For the open side, if you’re using an envelope closure, you’ll sew the two hemmed edges together with an overlap. If you’re using zippers, install them now according to the manufacturer’s instructions.
Method B: Cushion with Separate Sides (for deeper/thicker cushions)
- Cut one piece for the bottom and one piece for the top. Cut strips for the sides that are the height of your foam plus seam allowances. If your cushion is rectangular, you’ll have two strips for the length and two for the width.
- Sew the side strips together at their ends to form a continuous loop.
- Pin the bottom edge of this side loop to the bottom fabric piece, right sides together. Sew around, easing curves as needed.
- Pin the top edge of the side loop to the top fabric piece. If you’re using an envelope closure, one of your “top” pieces will be the main top panel, and the other will be the overlapping flap piece. If using a zipper, install it along the top edge before attaching the side loop. You’ll then sew the side loop to the top panel on three sides, leaving the zipper side open.
- Once all sides are attached and the zipper is in place (or you’re ready to create the envelope closure), sew the pieces together securely.
For Envelope Closures: Lay the unfluffed bottom piece and the top piece (that you hemmed on both long edges) right sides together. Align the raw edges. Position the top piece so that the hemmed, overlapped edges will be at the back of the cushion. Imagine sliding the foam in – the overlap should allow for this. Pin the side edges and the bottom edge. Sew around the three raw edges.
Step 4: Trim and Turn
Trim any excess fabric from your seams, especially at the corners, to reduce bulk. Be careful not to cut the stitching! Turn the cushion cover right side out. Use a blunt object (like a chopstick or the end of a pencil) to gently push out the corners for a crisp finish.
Step 5: Insert the Foam
Carefully slide your pre-cut foam insert into the fabric cover. If you made an envelope closure, this is where you tuck the foam in through the overlapping flaps. If you used a zipper, make sure it’s partially open before you start inserting!
Step 6: Finishing Touches
If you used an envelope closure, the overlapping fabric should now hold the foam snugly inside. If you used a zipper, zip it closed. For added durability and a professional look, you can topstitch around the edges of the cushion. This also helps prevent the inner seams from fraying.
Adding Piping (Optional)
If you want to add piping for a decorative edge:
- Cut fabric strips along the bias (or straight grain for less flexible fabric) equal to the length of your cushion edge plus seam allowances.
- Fold these strips in half around your piping cord and sew close to the cord to encase it.
- Sew this fabric-covered piping to the right side of your bottom cushion fabric piece along the edge, with the cord facing inwards.
- When you attach the top piece or side panels, the piping will be sandwiched between the layers, creating a durable and decorative edge.
Choosing the Right Outdoor Fabric: Key Features
The fabric you choose is perhaps the most critical element for creating long-lasting outdoor cushions. Not all fabrics are created equal when exposed to the elements.
| Fabric Type | Pros | Cons | Best For |
|---|---|---|---|
| Solution-Dyed Acrylics (e.g., Sunbrella) | Excellent UV resistance, highly water-repellent, mildew resistant, fade-resistant, breathable, soft feel. | Higher cost. | All outdoor applications, high-traffic areas, long-term exposure. |
| Polyester (Treated for Outdoor Use) | Good UV resistance, water-repellent, mildew resistant, durable, more affordable than acrylics. | Can be less breathable, may fade over very long periods. | General outdoor seating, covered patios, moderate sun exposure. |
| Olefin (Polypropylene) | Excellent stain and abrasion resistance, good UV resistance, lightweight, quick-drying. | Can feel a bit stiff, may pill over time. | High-use areas, quick-drying needs, budget-friendly. |
| Cotton Blends (Treated) | Comfortable, soft, can be dyed in vibrant colors, often more budget-friendly. | Less UV resistant, prone to mildew if not treated and properly cared for, can absorb water. | Covered porches, indoor/outdoor rooms, areas with less direct sun and rain. |
When looking for outdoor fabrics, always check the label for keywords like “UV resistant,” “water-repellent,” “mildew resistant,” and “outdoor use.” For great advice on fabric care and types, resources like those from the Garden Defender website (reputable gardening resource) can be very helpful.
Foam Selection for Outdoor Cushions
The right foam makes all the difference in comfort and longevity. For outdoor cushions, you want something that can withstand moisture and dry relatively quickly.
- High-Density Polyurethane Foam: This is a common and good choice. Look for a density of 1.8 lbs per cubic foot or higher, and a firmness (IFD/ILD) of 35-50 lbs. This ensures good support and durability.
- Reticulated Foam: This is a specialized foam where the internal cell structure is open. This allows air and water to pass through much more freely, making it ideal for outdoor use as it dries very quickly and resists mildew. It’s often more expensive but is the premium choice for wet environments.
- Foam Thickness: As mentioned, 3-6 inches is typical for most outdoor furniture. Measure your furniture and consider how much cushioning you desire.
It’s often best to purchase foam that is specifically sold as “outdoor foam” or “reticulated foam.” Standard upholstery foam can trap moisture and lead to mold and mildew growth within the cushion itself, which can be difficult to remove and can damage the foam and fabric.
Cushion Care and Maintenance
To keep your handmade outdoor cushions looking their best for years to come, a little care goes a long way.
- Regular Cleaning: Brush off loose dirt and debris regularly. For spills or stains, blot them immediately with a clean cloth.
- Spot Cleaning: Mix a mild soap solution with water. Gently scrub the affected area with a soft brush or sponge, rinse thoroughly with clean water, and allow to air dry completely.
- Deep Cleaning: If possible, remove the cushion covers and wash them according to the fabric manufacturer’s instructions. Many outdoor fabrics can be machine-washed on a gentle cycle with cold water.
- Drying: Always ensure cushions and covers are completely dry before storing them or putting them back on furniture. Air drying in the sun is great for this.
- Storage: During harsh weather or the off-season, store your cushions in a dry, well-ventilated place. Cushion storage bags or bins are ideal. Avoid plastic bags that can trap moisture.
- Mildew Prevention: Ensure good air circulation around your cushions when they are in use. Don’t leave them in perpetually damp conditions without allowing them to dry.
For more detailed garment care and fabric science insights, the FabricLink.com website offers excellent, up-to-date information on textiles and their care.
Frequently Asked Questions About Making Outdoor
