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The Cutting Table · a checklist answer

How do I get the foam back into my cushion cover?

Also asked as:they will not fit into the coversI unzipped it to wash and can't put it back

The foam is meant to look too big for its cover. That is the whole trick, and why a good cushion never wrinkles.

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The Elder of High Point · · Updated

Navy and white striped bay window seat cushion with an angled end, two ivory linen pillows and a fern on the sillSave
The cushion follows the bay's angled side exactly, so the navy stripe runs unbroken from wall to wall.

The quick answer

To put foam back in a cushion cover, fold the foam, not the cover: open the zipper past both corners, slip the foam into a thin plastic bag, fold it lengthwise and fill the far corners first. Firm foam is cut slightly larger than its cover on purpose, so use two people. Never trim it.

Get a quote for a foam insert

Why new foam is cut bigger than its cover

A buyer got in touch that the new foam was about 4 in (10 cm) bigger than the old pieces and would not go into the covers. Nothing was wrong. Firm, high-density foam is cut a little larger than its cover on purpose, so the fabric sits full and taut.

In my trade we would rather wrestle foam for ten minutes than look at a baggy cushion for ten years. More on the foam itself: foam inserts.

Refitting the foam, corner by corner

Clear a bed or a big table, and find a second pair of hands first.

  1. Why Bench and mattress covers zip in an L. Use the whole door.

  2. Why Bare foam grabs fabric. Draw the bag out once the foam is in.

  3. Why Fill the corners while the foam is still narrow; the rest follows.

  4. Why That leg is the hardest piece to seat.

  5. Why One person squeezes, the other walks the fabric forward. Small moves spare the seams.

  6. Why Tape about 2 in (5 cm) wide still slides. String and twine cut into foam.

  7. Why Press the cushion inward as you zip. A slight bulge at the zipper means a full-looking cover.

of 7 ticked. Tick them off as you write your order; nothing is saved or sent.

Key facts

  • Firm, high-density foam is cut slightly larger than its cover on purpose, so the fabric sits full and doesn't wrinkle.
  • Two people make the job easy: one compresses the foam, the other works the cover over it a little at a time.
  • Fitted covers are cut about 1/2 to 3/4 in (1-2 cm) under the measured thickness, because the fabric gives slightly.
  • On bench and mattress covers the zipper often runs in an L around two corners so the foam slides in and out.
  • Foam cushions are wrapped in polyester fiber with a protective layer, not a separate inner cover.
  • Covers wash at 86°F (30°C) at most on a gentle cycle; the foam itself is never washed.
  • Never trim the foam to make it fit.

Have it made

Have Harlan’s workshop cut this for you

Old upholsterers will tell you the real cutting happens in the conversation, long before the shears come out. Tell the workshop what you sit on, and they will talk it through with you. — Harlan

Leave your details and the workshop will call you to confirm measurements, fabric, foam and piping. No prices, dates or payment on this page: it is a request, not an order.

Fabric · Foam · Pipingwhat the workshop will confirm with you

Fabric
Fitted covers are cut about 1/2 to 3/4 in (1-2 cm) under the measured thickness, because…
Foam
Firm, high-density foam is cut slightly larger than its cover on purpose, so the fabric…
Piping
The corded seam edge: matching, contrast or none.
Only for this request: no marketing calls or texts. Outside the US, add the country code.
In inches: length × depth × thickness, plus any angles or cut corners.

* Required. A member of the workshop team will call you to talk it through; nothing is charged and nothing is made until you have agreed on every detail with them.

We use these details only to answer this request and make your cushion: your name and contact details, the cushion details and photos you send, the page you came from and the ad or link that brought you, if any. The workshop that makes the cushions receives them. We don't sell them or share them for advertising, and we delete requests after 24 months. Privacy notice for requests.

Nothing is made or charged until you approve the details.

Want to pick the shape and add photos? Use the full quote form

Damp cover or dry cover? The trade is split

Cover makers split here. Some fit a washed cover while it is slightly damp, because damp cloth gives. Others wait until it is dry, so no moisture gets shut in against the foam.

Where I land: wash at 86°F (30°C) at most on a gentle cycle and air-dry. If the nearly dry cover still fights you, fit it then and stand the cushion on its edge until it is dry through. Damp is not wet. See how to wash cushion covers.

Which shape is fighting you, my friend: a rectangle, or an L with a stubborn leg?

Trimming the foam or washing the non-slip bottom

  • Trimming the foam. It was cut large on purpose; trimmed, the cover stays baggy for good.
  • Washing the white non-slip bottom piece. It shrinks, and then the cover won't close; see covers that won't zip after washing.

Fold the foam, not the cover. The cover has a shape to keep; the foam will forgive you.

Harlan
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Buyer questions

  1. A common question

    My replacement foam looks bigger than the cover. Did you send the wrong size?

    The workshop's answer

    No. Firm, high-density foam is cut slightly larger than its cover on purpose, so the fabric stays full and smooth. Don't trim it. One person compresses the foam while the other works the cover over it, bit by bit.

  2. A common question

    I unzipped my floor sofa cover to wash it, and now I can't get it back on. Help?

    The workshop's answer

    The workshop sends a refitting video if you're stuck. The covers wash at 86°F (30°C) at most on a gentle cycle; take the white non-slip bottom piece off first, because it must not go in the machine.

  3. A common question

    Will a replacement cover fit my own foam snugly?

    The workshop's answer

    Yes, if the measurements are right. The fabric stretches slightly, so fitted covers are cut about 1/2 to 3/4 in (1-2 cm) under the measured thickness: a stack of about 8 1/4 in (21 cm) got a 7 7/8 in (20 cm) cover. Say whether the insert is foam or fiber-filled.

Questions buyers ask next

Should I wait before fitting a cover over foam fresh out of vacuum packing?

Yes. Vacuum-packed floor sofa foam regains its shape in about 36-48 hours, and one workshop reply advised waiting that long before fitting covers. Kneading the bare foam helps it recover.

Is there an inner cover on the foam that should stay on when I refit?

Foam cushions have no separate inner cover; the foam is wrapped in polyester fiber with a protective layer, and that stays on. Shredded-foam pillows are different: their fill has its own inner cover.

Which way should the zipper face once the cushion is back in place?

Down or back: on the underside, or on the back edge against the wall, window or chair back. If you can see it, the cushion is probably upside down.