Making comfortable and durable outdoor chair cushions can extend the life of your patio furniture and make it more enjoyable to relax outdoors. With the right materials and some basic sewing skills, you can create custom cushions tailored specifically for your chairs. Here is a step-by-step guide on how to make outdoor chair cushions yourself.

Choose the Right Fabric

When selecting fabric, durability and weather resistance are key factors for outdoor cushions. Consider these fabric options:

Canvas

Extremely durable and woven tightly to be water-resistant
Available in many colors and prints
Less expensive than other outdoor fabrics
Can fade faster than acrylic or polyester

Acrylic

Colorfast and resists fading from sun exposure
Withstands moisture and mildew
More expensive than canvas
Not as breathable as other fabrics

Polyester

Colorfast, strong, and weather resistant
Breathable fabric that won’t trap moisture
Typically used for boat cushions
Can be pricier than canvas

Performance Fabrics

Advanced synthetic blends designed for outdoor use
Repel water, resist stains, and offer UV protection
Brands like Sunbrella and Outdura are popular choices
Most expensive option

Opt for solution-dyed acrylics or polyester if you want vivid, fade-resistant colors. For neutral tones, canvas is a budget-friendly choice.

Select Cushion Fill Material

The fill material inside the cushions impacts their comfort, support, and durability. Consider these options:

Polyester Fiberfill

Traditional cushion fill made from polyester staple fiber
Provides softness and bounce-back
Lower price point than foam options
Needs occasional fluffing as it compacts

Polyurethane Foam

Long-lasting supportive foam cushions
Outlasts fiberfill and resists compacting
Dense foam offers firmness, softer grades add comfort
Moisture-resistant and mildew-proof
More expensive than fiberfill

Polyester Hollowfill

Hollow polyester fibers that mimic down filling
Lightweight and provides a down-like look
Less prone to clumping than fiberfill
Retains loft and shape well

Natural Fillings

Materials like down, feathers, wool, cotton
Not recommended for outdoor cushions
Absorb moisture and require drying out

Polyester fiberfill or foam are the best bets for outdoor durability. Select a high-density foam or mix foam and fiberfill for cushions that hold their shape.

Take Precise Measurements

Measure the length, width, and height of your chair’s seating area. Add 2-3 inches to the length and width for a cushion with ample overhang. Record the exact dimensions to create covers that fit snugly over the cushions. Loose covers are prone to sliding out of place.

Sew the Cushion Covers

With your fabric selected and measurements in hand, you can sew cushion covers tailored to your chairs. Here’s an overview of the process:

Cut fabric panels

Cut the top and bottom panels to the cushion’s length and width measurements.
Cut the side panels to the cushion’s height plus 1.5 inches.

Sew the panels

Sew the side panels to the top and bottom panels with 1⁄2 inch seam allowances.
Leave an 8-10 inch opening along one seam for inserting the fill.
Reinforce corners and seams with extra stitching for durability.

Add zipper closure

Insert zipper in opening to enclose fill and remove covers for washing.
Opt for zippers intended for outdoor use. Plastic coil types withstand weather best.

Finish edges

Finish seam allowances with serging or zigzag stitches to prevent fraying.
For a tidy look, hem the edges or bind them with coordinating fabric strips.

With the covers ready, you can add filler and ties to complete the cushions.

Insert Cushion Filler

Before stuffing the cushion covers, make inserts to add shape and support.

Cut foam base

From high-density foam, cut a base 11⁄2 inches smaller than the cover dimensions.
Cut foam depth about 1 inch less than total cushion height.

Add softer fill layers

Top foam base with polyfill stuffing for a softer feel.
For down-like look, use hollowfill polyester on top.

Insert into cover

Place assembled inserts into cover and distribute filling evenly.
Fill until cushion achieves desired fullness.

Well-filled cushions hold their form better than understuffed ones. Compress and squeeze inserts to fit into covers.

Add Ties to Secure Cushions

Apply ties to the underside of cushions to keep them fixed in place on chairs.

Sew fabric ties

Cut 4 ties per cushion from coordinating fabric, 1” wide x 16” long.
Sew ties at corners, 4-6 inches from edges with fabric glue for reinforcement.

Attach ties to chair

Tie loose ends under chair in pairs to prevent cushion slippage.
For removable cushions, use ties that can be fastened and unfastened.

Elastic loops and hook and loop fastener tape work well for detachable ties.

Weatherproof and Protect Cushions

Since your cushions will live outdoors, take a few additional steps to protect them:

Spray fabric with a water repellent like Scotchgard.
Apply fabric sealant along seams and edges.
Cover cushions when not in use or store indoors.
Allow cushions to air dry before putting covers back on.
Wash removable covers occasionally and spot clean stains.

With frequent use, outdoor cushions will need replacing every 2-3 years. Well-made covers can be reused with new filler.

Frequently Asked Questions

What size should I make outdoor cushions?

Measure the length and width of your chair’s seating area, then add 2 to 3 inches to those dimensions for adequate overhang when cutting cushion covers. Cushion height depends on how thick you want them, but 4 to 6 inches is typical.

How do I stop outdoor cushions from sliding?

Attaching fabric ties to the bottom corners of cushions secures them to chairs and prevents slippage. Using sufficiently snug cushion covers also helps them stay put.

What stitching technique should be used?

For outdoor cushions, select a durable straight or zigzag stitch and use a medium-long stitch length. Reinforce seams and stress points by stitching over them twice. Outdoor-rated nylon thread is stronger than standard all-purpose thread.

Should I make cushions removable?

Yes, making cushions removable with ties or zippers allows you to take covers off for cleaning and replace fillings when they flatten. Non-removable cushions are harder to maintain over time.

How do I make cushions last longer outside?

Choosing fade and water resistant outdoor fabrics is key. Also spray fabric sealant on seams, allow cushions to fully dry before covering, and stow them when not in use. Replace fillings every few years for fresh cushioning.

Conclusion

Creating your own outdoor chair cushions is an extremely rewarding project that can breathe new life into tired patio furniture. Adjust the size, fabric patterns, and fill levels to make cushions that meet your style and comfort preferences. With the right materials and careful construction focused on durability, you can enjoy your custom cushions for seasons to come while relaxing outdoors!

How to Make Outdoor Chair Cushions