---
title: "Custom Zippered Cushion Covers for Bench and Seat Foam"
url: "https://cushionguide.com/cushions/cushion-covers/"
section: "The Cushion Atlas"
author: "Élodie Marchand, The Colorist of New Orleans"
author_url: "https://cushionguide.com/masters/elodie/"
published: "2026-02-23"
updated: "2026-09-24"
keywords: "custom cushion covers, replacement cushion covers, cushion covers for existing foam, zippered cushion covers, custom box cushion covers, floor sofa replacement covers"
---

# Custom cushion covers and bench cushion covers, cut to the foam you have

*Often the foam is still good and only the fabric has tired, faded or fallen out of love with the room. A new cover, sewn to that foam, is the gentlest way to change a seat.*

> **The quick answer:** Custom cushion covers are zippered, removable covers sewn to the exact length, width and thickness of foam you already own, with no filling inside. They cost less than a new filled cushion and wash at 86°F (30°C) on a gentle cycle; ask for the making time with your quote. Always give the insert thickness, and measure tapered shapes front and back.

![Front view of a caramel bouclé bench cushion with its side zipper half open, showing a pale inner layer, on an oak bench](https://cushionguide.com/media/cushion-covers/caramel-boucle-cushion-side-zipper-front-view-1024.webp "A zipper along the side panel means the caramel cover can come off without taking the bench apart.")

## When the foam is fine and the fabric is not

A cushion cover is the part of a cushion that lives in public. The foam inside can stay sound for years while the fabric fades by the window, takes a stain, or stops agreeing with a newly painted wall. That is when custom cushion covers make sense: new zippered covers, sewn to the foam you already have, with nothing inside.

They suit sofa seats with good inserts, bench and window seat pads, porch swing and deck box cushions, even a mini crib mattress turned play mat. One buyer in the US chose brown velvet for six sofa cushions and, because the inserts were still good, cut the quote substantially by switching to covers only. In another quote, a single replacement cover came to about 40% of a new cushion with foam.

New cushions live under [bench cushions](https://cushionguide.com/cushions/bench-cushions/) and [foam inserts](https://cushionguide.com/cushions/foam-inserts/); floor sofa spares under [modular floor sofas](https://cushionguide.com/cushions/modular-floor-sofas/).

## Measuring foam you already own

|   |   |
|---|---|
| Length and width | The foam, edge to edge, to the nearest 1/4 in; write the exact numbers in the personalization box |
| Thickness | Always give it. Three striped bench covers were sewn for 3 in (7.5 cm) inserts because the buyer said so |
| Tapered pieces | Front and back separately: one chair cover was 17 in (43 cm) at the back, 19 in (48 cm) at the front, 19 in deep, 3.5 in (9 cm) thick |
| Mattress covers | Made 1/2 to 3/4 in (1-2 cm) under the measured thickness, because the fabric stretches slightly |
| Zipper | Standard, hidden on the back edge or the underside; you choose the side. Bench and mattress covers wrap it around two corners |
| Make time | Custom covers without foam: ask for the current making time |

## Box edges, piping lines and where the zipper hides

Most covers are box covers: a top, a bottom and a band around the sides, with piping at each seam or none at all. Piping is where a cover shows its tailoring. Ivory, olive and emerald velvet, each with a welt in another shade, or burgundy piping around a dusty rose weave, draw the outline the way a pencil line finishes a sketch. A clean unpiped seam suits chenille and soft textures.

The [zipper](https://cushionguide.com/glossary/#hidden-zipper) sits on the back edge, facing the wall, or on the underside, and you pick the side. On bench and mattress covers it runs around two corners, an [L-shaped wraparound](https://cushionguide.com/glossary/#wraparound-zipper), so the foam slides out without a wrestle. More in [where the zipper goes](https://cushionguide.com/guides/cushion-zipper-placement/).

## Fabrics for a second life

A new cover is a chance to change the room's key. Price follows size far more than fabric, so choose for the life the seat leads.

- [Velvet](https://cushionguide.com/fabrics/velvet/): burgundy, aqua and emerald with a sheen that moves with the light.
- [Linen-look weaves](https://cushionguide.com/fabrics/linen-look-fabrics/): the quiet workhorse, from oatmeal to dusty rose.
- [Bouclé and teddy](https://cushionguide.com/fabrics/boucle-and-teddy/): caramel and forest green loops.
- [Corduroy](https://cushionguide.com/fabrics/corduroy/): floor sofa covers are 100% polyester plush corduroy.
- [Performance and pet-friendly weaves](https://cushionguide.com/fabrics/performance-and-pet-friendly/): a pebbled sage for homes where the cat sits first.

Covers are cut from fabrics from a mill certified to OEKO-TEX Standard 100 (03.T.3239). To match an existing color, order a sample and look at it in daylight. Extra fabric is sold by the yard, on rolls about 55 in (140 cm) wide, some about 79 in (2 m).

## Thickness, stretch and a cover that looks full

A cover only looks tailored when the foam fills it. New firm foam is cut slightly larger than its cover for exactly this reason. When you order covers for your own foam, the cover is sewn to your numbers so it closes snugly; fitted mattress covers go 1/2 to 3/4 in (1-2 cm) under the measured thickness, because the fabric gives a little.

Compare outline and thickness before you put a standard mattress into a custom cover. One floor sofa owner in the US wanted a spare 39 x 79 in (99 x 200 cm) cover; the cushion inside was about 6.5 in (17 cm) thick, while a twin XL mattress usually starts around 8 in (20 cm). Nearly the same outline, a very different fit.

## Three striped covers for three bench seats

A buyer in the US wanted new covers for three bench seats in a terracotta and red stripe story. Two were 16.5 x 46 in (42 x 117 cm) and 16.5 x 29.5 in (42 x 75 cm), with a terracotta body and a vertical stripe for the piping. The third, a narrow 11.25 x 45 in (29 x 114 cm), reversed the recipe: striped body, terracotta piping, and ties set 6 in (15 cm) in from each short end.

She already had foam, so she chose covers only and gave the one number that decides everything: the inserts were 3 in (7.5 cm) thick.

## Cover mistakes we see, and the fix for each

- ✗ Leaving out the insert thickness on a covers-only order. Length and width are only two of the three numbers.
- ✗ Measuring a tapered cushion once, across the middle. Give the front and back widths; half an inch at the front changes the whole cover.
- ✗ Washing at 30°F. The label means 86°F (30°C) on a gentle cycle, then air dry.
- ✗ Forcing the zipper closed over a freshly washed cover. Refit it while slightly damp and never pull hard on the zipper.
- ✗ Unrolling every cover in a multi-piece pack before checking one color. Check one end first, so a wrong set can go back sealed.

> Cushion covers wash at 86°F, which is 30°C, not 30°F. Air dry them and zip them back on while still slightly damp.
>
> — Élodie

## Spare sets, seasonal swaps and the tools

A spare set of covers is the simplest restyling I know. Floor sofa owners keep one set on while the other is in the wash, or trade ink navy for brick when the evenings turn cool. Which color would your seat wear in winter, my friends, if it could choose?

If you plan to sew something of your own from the same cloth, the [fabric yardage calculator](https://cushionguide.com/studio/fabric-yardage-calculator/) works out how much to buy. Then read [covers only: measuring foam you already own](https://cushionguide.com/guides/cushion-covers-for-existing-foam/), [how to wash cushion covers](https://cushionguide.com/guides/how-to-wash-cushion-covers/) and, for floor sofas, [replacement covers: fit and color change](https://cushionguide.com/guides/floor-sofa-replacement-covers/).

> **Tailor's margin:** Cushion covers for foam you already own need three numbers: length, width and the insert thickness, measured on the foam itself.

## Bench cushion covers for foam you already own

A bench cushion cover is the most common covers-only order: the foam is fine, the fabric is tired. Measure the bare insert, or the old cover seam to seam with the foam still inside, for length, depth and thickness, and send those numbers without adding anything; covers are cut to the insert and the fabric's slight stretch is allowed for. Say where the zipper should go, usually the back edge and around two corners so the foam slides out, and whether you want ties or a non-slip bottom panel, since neither is added automatically. Piping comes standard on covers and can match or contrast. Other cover makers quote tolerances such as 0 to 1 in under the ordered size, so ask how close yours will come.

## Zippered cover or stretch cover

|   | Zippered cover cut to size | Stretch (elastic) cover |
|---|---|---|
| Fit | Cut to your insert's exact size | Stretches over a range of sizes |
| Look | Crisp, tailored edges and piping | Softer; can wrinkle on firm box cushions |
| Best on | Firm foam benches and seats | Soft, rounded sofa cushions |
| Washing | Unzip and machine wash | Pull off and machine wash |
| From the workshop | Yes, zipper-only | No; buy ready-made |

## Buyer questions

**A common question:** How do I get a price for replacement cushion covers?

**The workshop's answer:** Use the cover-only listing: pick the size range for each piece, for example two seat covers and two back covers, and the price shows with any running discount already applied. Write the exact sizes, main fabric code and piping code in personalization; contrast piping is fine. If only the cover is damaged, order just that. In one quote a single cover came to about 40% of a new cushion with foam.

**A common question:** Only one cover on my floor sofa is damaged. Can I replace just that one?

**The workshop's answer:** Yes. Single covers are sold when one tears or its zipper breaks, and the shop sets up a listing for the exact piece, whether base, straight backrest, corner backrest, armrest or ottoman, in the color of your set. Partial sets, such as just the two straight backrests, can be ordered too. Floor sofa replacement covers come in the standard sizes only.

**A common question:** What temperature and cycle should I wash the covers on?

**The workshop's answer:** Take the cover off the foam and machine wash at no more than 86°F (30°C); the 30 on the label is Celsius, not Fahrenheit. Use a gentle, delicate or cold cycle, the gentle program for corduroy, a mild detergent and no bleach, and turn the cover inside out if you can. Air dry, and iron on low if needed. The white non-slip bottoms on floor sofas stay out of the machine.

**A common question:** Can I order a second set of floor sofa covers in another color?

**The workshop's answer:** Yes. Buy the sofa from its listing and the shop sends a separate link for an extra cover set in the color you choose. It can ship with the sofa, or later, since the link stays active. The fillings have their own inner covers, so you can swap colors with the seasons or keep a spare set for wash day. Buying two or three sets lowers the price per set.

**A common question:** Can I buy the same fabric by the yard to recover an ottoman?

**The workshop's answer:** Yes. Samples and cut lengths are sold through the fabric-samples listing, and larger pieces through a custom order link; send the fabric code and how much you need. Extra fabric can ship with your cushions. Roll width depends on the fabric, about 55 in (140 cm) for most and about 79 in (2 m) for some, which sets how large one piece can be.

**A common question:** Will your replacement covers fit a teddy floor sofa I bought from another brand?

**The workshop's answer:** Usually, if the dimensions match. The seat covers fit 79 x 39 x 6.5 in (200 x 100 x 17 cm) pieces and the L-shaped backrest covers 39 x 39 x 15 in (100 x 100 x 39 cm), very close to the best-known designer teddy sofa. Measure each piece, especially the height; a foam-filled backrest from another maker may sit slightly loose. To match an existing color, order a fabric sample first.

## Questions buyers ask next

### Can a covers-only order be button-tufted?

No. Tufting is possible only when the workshop makes the filling, because the buttons are sewn through cover and fill together and the piece is closed by hand. A covers-only order is made as a plain zippered cover without tufting.

### How long do replacement covers take to arrive?

Custom covers without foam still need cutting and sewing, and replacement covers also need fabric sourcing and delivery. Ask the workshop for current times in writing, and if you have a date in mind, write it in the order note and message right after ordering.

### Why is a new mattress cover a little shallower than my mattress?

On purpose. Fitted mattress covers are sewn 1/2 to 3/4 in (1-2 cm) under the measured thickness because the fabric stretches slightly. That small difference keeps the cover smooth once the fabric relaxes.

### Which side of the cushion does the zipper go on?

The back edge, facing the wall, or the underside, and you can choose. On bench and mattress covers the zipper usually wraps around two corners in an L, so the foam slides in and out without folding.

### What happens if a cover arrives in the wrong size or color?

For workshop errors such as a wrong size, reversed colors, a broken zipper, an open seam or a zipper on the wrong side, photograph the fault the day the box opens and message the workshop. Ask it to confirm the fix in writing; in past cases it was a remake, a new cover or a replacement part, often without asking for the item back.

### Can you make a cover for foam I bought somewhere else?

Yes. Covers only are sewn to any size, including foam from another maker; write the foam's length, width and thickness. For shaped pieces the workshop asks for a drawing with measurements and a photo of the space.

### Can a replacement bench cushion cover have ties or a non-slip bottom?

Yes. Ties can be sewn into the seams wherever you mark them, at the corners or along the back edge, and a non-slip bottom panel can replace the whole underside so the cover grips the bench by friction. Say which you want in the order note along with the foam's length, width and thickness, since neither is added automatically.

## Related at the atelier

- [Zippered Cushion Covers With Contrast Piping: What Goes Inside](https://cushionguide.com/readings/four-zippered-box-cushion-covers-contrast-piping/): A zippered box cushion cover is only half a cushion: its box height sets how much foam goes inside, and doubling the height from 6 in to 12 in roughly doubles the fill and the cost.
- [Zippered Cushion Cover in Forest Green Bouclé Through the Year](https://cushionguide.com/readings/hidden-zipper-forest-green-boucle-cushion-cover/): A zippered cushion cover in bouclé works all year when the zipper runs along the back boxing seam, where it faces the wall and the loops close over the tape.
- [Are the cushion covers removable and machine washable?](https://cushionguide.com/answers/removable-machine-washable-cushion-covers/): Yes, every zippered cushion cover is removable and machine washable, velvet and linen included, on full cushions and cover-only orders alike.
- [Will your replacement covers fit a teddy floor sofa from another brand?](https://cushionguide.com/answers/teddy-sofa-covers-fit-other-brands/): Teddy sofa replacement covers usually fit another brand's sofa when the dimensions match: seats of 78 x 39 x 6.5 in (200 x 100 x 17 cm) and L-shaped backrests of 39 x 39 x 15 in (100 x 100 x 39 cm)…
- [Replacement covers for a floor sofa: fit, color change and single pieces](https://cushionguide.com/guides/floor-sofa-replacement-covers/): Floor sofa replacement covers are zippered covers sold without foam or metal bars: a standard set is two 78 x 39 x 6.5 in (200 x 100 x 17 cm) seat covers and two 39 x 39 x 15 in (100 x 100 x 39 cm)…
- [When the patio set outlives its cushions](https://cushionguide.com/concepts/patio-set-cushion-refresh/): If the foam in your patio set still springs back, order replacement covers made to each insert's size, measured seam to seam; if the foam is flat, order full replacement patio cushions sized to the…
- [Cut-to-size foam vs a finished cushion: the honest comparison](https://cushionguide.com/guides/cut-to-size-foam-vs-finished-cushion/)

*With color and care — Élodie*

---

Written by Élodie Marchand (https://cushionguide.com/masters/elodie/) for CushionGuide (https://cushionguide.com/about/). The site explains made-to-measure cushions and the partner workshop makes them; measurements are in inches first. This Markdown mirrors the page at https://cushionguide.com/cushions/cushion-covers/