Outdoor cushions often wear out in two different ways. Sometimes the cover is faded, stained or torn, but the foam inside is still comfortable. Other times the cover looks acceptable, but the foam has collapsed, gone lumpy or started to smell musty. If you are planning a proper refresh, it helps to think about the foam insert and cover together.
Resort Style Bean Bags makes custom outdoor cushion covers. We do not supply replacement foam inserts, but we can help you work out what information your foam supplier will need, and we can make covers to suit existing or newly sourced foam.
This guide is written for customers who are replacing patio cushion foam, ordering new covers, or starting a new outdoor seating project from scratch.
Do you need new foam, new covers, or both?
If the cushion still feels supportive and dry, you may only need new covers. If the foam is flat, crumbling, holding water or no longer comfortable, it is usually better to source new foam and have the covers made to fit the new inserts.
Start by removing the cover and checking the insert itself. A tired cover can make a cushion look worse than it is, but old foam has a feel of its own. Sit on it, press the corners, smell it and check whether it springs back.
Signs the foam may need replacing include:
- The cushion stays compressed after you sit on it.
- The corners have rounded off or collapsed.
- The insert feels damp even after time in the air.
- There is a musty smell inside the cover.
- The old foam no longer fills the cover properly.
If the foam is still good, custom covers can be made to suit it. If the foam is not worth keeping, speak to a foam manufacturer before finalising the cover dimensions.
What should you ask a foam supplier?
Ask your foam supplier about outdoor suitability, finished size, thickness, firmness, drainage, wrap and whether the foam will be used under cover or in exposed weather. The answer may change depending on the chair, bench, daybed or lounge you are refreshing.
Foam is not one-size-fits-all. A dining chair cushion, a long bench seat and a deep outdoor lounge cushion all need different support. The right insert depends on how the seat is used, how thick the cushion can be and whether the furniture sits in full weather.
Useful questions for your foam supplier include:
- Is this foam suitable for outdoor use?
- What firmness do you recommend for this cushion thickness?
- Should the insert be wrapped for a softer, fuller finish?
- Will the foam hold water if the cushion gets wet?
- Can you cut the foam to the finished size I need?
- Should I allow for compression when ordering the cover?
Once you have those answers, we can use the finished insert dimensions to quote the covers. If you are not sure what to ask, call us on 0411 655 360 and we can help you prepare before speaking to the foam supplier.
How should you measure for replacement foam and covers?
Measure the finished cushion size you want, not only the old cushion size. Old foam may have shrunk, flattened or stretched the cover, so photos and context are important. Measure in centimetres and note the shape clearly.
If you are replacing foam for an existing cover, measure the old insert and the cover. If you are replacing both, measure the furniture space as well. The furniture frame often tells the truth better than an old cushion that has been squashed for years.
Measure:
- Width from left to right.
- Depth from front to back.
- Thickness from top to bottom.
- Any taper, curve, notch or angled back.
- The furniture seat area the cushion needs to sit on.
For long bench cushions, measure at a few points. Built-in seating can be slightly out of square, especially on timber decks and masonry benches. A photo with a tape measure in place is often useful.
Can custom covers work for complete refurbs and new projects?
Yes. Custom cushion covers are not only for old inserts. They are often a good choice for new outdoor seating, full furniture refurbs, daybeds, built-in benches and projects where the customer is sourcing fresh foam separately.
This is an important point. A custom cover is not only a rescue option for a tired cushion. It can also be the finishing piece for a new project where you want the seating to look neat from the start.
For example, you might be building a bench seat along a deck, replacing cushions on a quality outdoor lounge, or refreshing a set of patio chairs with new foam and covers at the same time. In those cases, the best result usually comes from planning the insert and cover together.
We have made many covers from customer measurements, and the finished covers have fitted properly because we check the details before making them. If the measurements, photos and foam plan do not line up, we will ask questions. That extra step matters.
Which cover details matter when the foam is new?
New foam can make a cushion look plump and clean again, but the cover still needs the right construction. A poor cover fit can make good foam look untidy.
Consider:
- Whether the cover needs boxed sides for thicker foam.
- Whether piping will give the cushion a more tailored finish.
- Whether the zip position makes the cover easy to remove.
- Whether ties, tabs or velcro are needed to keep the cushion in place.
- Whether the fabric colour will hide everyday outdoor marks.
Australia’s sun is a major factor in outdoor material choices. ARPANSA explains that UV exposure in Australia is high enough to require real sun protection planning for people outdoors. Outdoor furniture is not skin, but the same environment is why fabric selection matters. The ARPANSA overview is here: sun exposure in Australia.
How to prepare your quote request
A clear quote request saves time and reduces the chance of a fit problem.
Send:
- Photos of the furniture and existing cushions.
- Measurements of the old cushion, if you have one.
- Measurements of the furniture space.
- Whether the foam is existing or new.
- The finished foam size, if your foam supplier has confirmed it.
- Your preferred fabric colour or style.
- Any details such as zips, piping, ties or tabs.
If you are unsure, call first. It is much easier to clarify the measuring process before the foam is cut or the cover is made.
Frequently Asked Questions
Does Resort Style Bean Bags supply foam inserts?
No. We make custom outdoor cushion covers, not foam or cushion inserts. We can still help you understand the measurements and details you need, and we can recommend foam manufacturers where appropriate.
Should I order foam before ordering the covers?
You can, but it is best to plan both together. The finished foam size affects the cover fit, and the cover design may affect how the insert should be cut or wrapped.
Can I reuse my old foam?
Yes, if it is still comfortable, dry and in good shape. If it has flattened, smells musty or no longer fills the cover properly, new foam is usually the better long-term choice.
What if I do not know what foam type I need?
Speak with a foam supplier and explain where the cushion will be used, how thick it needs to be and whether it will be exposed to weather. If you need help preparing that conversation, call us on 0411 655 360.