If your outdoor chairs still have a good frame but the cushions are faded, split, thin or no longer suit the space, custom covers can be a very practical fix. You do not always need to replace the whole setting. In many cases, new covers made to the right size can make your patio chairs, dining chairs or occasional outdoor seats feel fresh again.
At Resort Style Bean Bags, we make custom outdoor cushion covers for Australian outdoor spaces. That means the cover is made to suit your measurements, fabric preference and the way the chair is actually used. It is especially useful when store-bought cushions are nearly right but not quite right.
This guide is for customers comparing Australian-made outdoor chair cushion covers, not for people looking for a generic cushion from a chain store. The aim is simple: help you work out what matters before you ask for a quote.
When should you choose custom chair cushion covers?
Choose custom chair cushion covers when your furniture is worth keeping, the existing cushion size is hard to match, or you want a better outdoor fabric than the original cover. Custom covers are also useful for new projects where you already have foam or plan to source foam separately.
Outdoor chair cushions often fail before the furniture frame does. Timber, aluminium and wicker-style frames can keep going for years, while the fabric takes the hit from sun, rain, sunscreen, food and regular use.
Custom covers are a good option if the cushion shape is unusual, the chair has rounded corners, the back cushion needs a special height, or the seat cushion has ties, tabs or a shaped front edge. They also make sense when you want the whole outdoor area to look more considered, instead of mixing several near-matching replacements.
If the foam or insert is still comfortable, the cover can usually be made to fit that existing insert. If the foam has collapsed, smells musty or no longer supports you, you can still use custom covers for a full refresh. We do not supply foam or cushion inserts, but we can talk you through what to ask a foam supplier so the new covers and inserts work together.
What should you measure before requesting a quote?
Measure the width, depth and thickness of each cushion, then note any shape details such as rounded corners, tapered edges, boxed sides, ties, zips or separate back cushions. A few clear photos are often just as helpful as the measurements.
Most quote delays happen because the cushion shape is not clear. A dining chair seat cushion might look rectangular at first glance, but the back corners may be rounded, the front edge may curve, or the cushion may taper to fit between chair arms.
For each chair cushion, measure in centimetres:
- Width from left to right across the widest point.
- Depth from the front edge to the back edge.
- Thickness from top to bottom.
- Back cushion height and width, if the chair has a separate back cushion.
- The position of ties, tabs, velcro or other fasteners.
Do not worry if you are unsure. We have made many covers from customer measurements and photos, and the finished covers have fitted correctly because we check the details before making them. If a measurement does not look right, we will ask. If you are stuck, you can call us on 0411 655 360 before sending the quote request.
Which outdoor fabric is best for Australian chair cushions?
For Australian chair cushions, look for an outdoor fabric that balances UV resistance, water resistance, comfort and cleanability. The best choice depends on whether the chairs sit under cover, beside a pool, near the coast or in full afternoon sun.
Australia is tough on outdoor fabric. ARPANSA notes that Australia has high UV exposure, and outdoor furniture can sit in that light for hours at a time. You can read more about local UV exposure from ARPANSA.
For chair cushion covers, the practical questions are:
- Will the chairs be left outside or stored under cover?
- Are they exposed to sunscreen, chlorine or salt air?
- Do you want a plain colour, stripe, texture or patterned fabric?
- Do you need the covers to be removable for cleaning?
- Will the fabric sit against bare skin in summer?
Olefin is often a strong choice for outdoor use because it is colourfast, practical and comfortable for Australian patios. Some customers also ask about Sunbrella or other outdoor fabrics. The right option depends on the look you want, the exposure level and the budget for the project.
Do custom covers work for new cushions as well as replacement covers?
Yes. Custom outdoor chair cushion covers can work for new projects, full refurbs and existing cushion makeovers. The key is making sure the cover dimensions match the foam or insert that will go inside.
Some customers already have good foam and only need new covers. Others are building a new outdoor dining area, replacing all the foam and covers together, or fitting cushions to chairs that never came with proper outdoor pads.
We do not provide the foam, but that does not stop the project. If your inserts need replacing, we can help you understand what details to confirm with a foam manufacturer, such as finished cushion size, foam thickness and whether the insert should have a soft wrap for a smoother finish.
For a neat result, it is better to plan the cover and insert together than to buy foam first and hope the cover will work later. If you already have foam, measure it carefully and send photos so we can see the shape.
What details make chair cushion covers look professionally made?
A good chair cushion cover is not only about fabric. Small construction details make a large difference to the fit and finish.
- Boxed edges help thicker cushions hold their shape.
- Piping can give a more tailored look.
- Hidden zips make covers easier to remove.
- Ties or tabs can stop cushions moving on dining chairs.
- Matching or coordinated fabrics can pull a whole outdoor area together.
If the chairs are used daily, practical details matter more than decorative ones. A white fabric may look beautiful in photos, but a mid-tone texture might be easier to live with around children, pets, gum leaves and barbecue dinners.
How to prepare a simple quote request
You do not need a technical drawing to ask for a quote. A clear message with photos is usually enough to get started.
Send:
- The number of chair cushions you need covered.
- Measurements in centimetres for each cushion type.
- Photos from above, side-on and with the cushion on the chair.
- Whether you are keeping the existing foam or sourcing new foam.
- Your preferred colour, fabric style or general look.
- Any fastening details, such as ties or velcro.
If you have several matching chairs, measure more than one cushion. Outdoor furniture can move, squash or stretch over time, and small differences can matter when the cover needs to fit properly.
Frequently Asked Questions
Do you make the foam inserts as well?
No. Resort Style Bean Bags makes custom cushion covers, not foam or cushion inserts. If you need new foam for a full refresh, we can help you understand what to ask a foam supplier and can recommend foam manufacturers where appropriate.
Can I order covers if my chair cushions are an unusual shape?
Yes, unusual shapes are one of the main reasons people choose custom covers. Send photos and measurements, including the widest points, curves, tapers and any fasteners, so the quote can be checked properly.
What if I measure incorrectly?
We will help you check the important measurements before making the covers. If something looks inconsistent, we will ask for clarification rather than guessing. You can also call 0411 655 360 if you need help before sending your quote request.
Are custom outdoor chair cushion covers worth it?
They are worth considering when the furniture frame is still good, the cushions are hard to replace off the shelf, or you want a better finish than a generic replacement. They can be especially useful for quality outdoor dining chairs and patio sets.