Sewing your own outdoor cushions can be a fun and rewarding project. With some basic sewing skills and the right materials, you can create durable and stylish cushions for your patio, deck or garden. Here is a step-by-step guide on how to sew an outdoor cushion.

Introduction

Outdoor cushions allow you to comfortably enjoy your outdoor living space. Store-bought outdoor cushions can be expensive, plus mass-produced cushions may not provide the right fit and flair for your space. Sewing your own gives you full control over the fabric selection, size, shape and style. With the correct techniques and materials, a homemade outdoor cushion can be just as durable as a store-bought one.

Things You’ll Need

Before starting your outdoor cushion project, you’ll need to gather these supplies:

• Outdoor fabric: Look for acrylic, olefin or polyester fabric that is intended for outdoor use. Stay away from cotton, which absorbs moisture and promotes mildew.
• Batting: Use polyester quilt batting that resists mildew and is designed for outdoor projects.
• Thread: Opt for thread made from polyester, nylon or polyester wrapped cotton. These are less prone to UV damage.
• Scissors and ruler: You’ll need fabric scissors for cutting. A ruler helps make neat, straight cuts.
• Sewing machine: A standard home sewing machine will work for this project. Outdoor fabrics can be thick, so make sure your machine can handle multiple fabric layers.
• Pins, needles: Stock up on straight pins and hand-sewing needles to assemble your cushion.
• Closure: Zippers, buttons, hooks or Velcro can all securely close your cushion. Ensure closures are also UV and weather resistant.

Cushion Measurements

Before cutting, determine the size of the cushion you want to make. Measure the furniture you want to cover, such as a patio chair, bench or chaise lounge. Add several extra inches to the length and width measurements to account for the seam allowances and cushion overlap. It is better for the cushion to be slightly large than to end up too small for the furniture.

Cutting Fabric Panels

With your measurements, you can now calculate the size of fabric needed. It’s best to cut panels bigger than your finished cushion size. This gives you ample fabric to work with when assembling.

Cut two panels the same size for the cushion front and back. Then cut four panels the same size for the sides. The side panels should be several inches taller than the front and back panels to create a “boxed” cushion with structure.

Use fabric scissors to carefully cut along the edges of a ruler or tape measure to ensure straight lines.

Sew Side Panels

Take two of the side panels and place them together with the right sides facing in. Sew along the long edge, leaving the short ends open. Repeat with the other two side panels.

Use a 1/2 inch seam allowance. Backstitch at the start and end for a reinforced seam. Press the seams open.

Sewing the edges together forms the side border of the cushion. Make sure not to sew the short ends shut. Those remain open for inserting the front, back and batting.

Attach Front and Back Panels

Now take one of the side borders and align it to one of the front/back fabric panels, right sides together. The side border should overlap the front/back panel by several inches on each side.

Sew the side border to the panel along the overlapping edges. Repeat with the opposite side border and the other front/back panel.

When sewn together, this creates a fabric shell with only two open ends.

Insert Batting

Cut a piece of quilt batting the same size as your fabric shell. Place the batting inside the cover through one of the open ends. The batting should fully fill the cover and reach all four corners.

Use a hand-sewing needle and thread to stab stitch the batting in place, closing up the open ends as you work your way around.

Add Closure

To finish the cushion, you need to close the final seam. Centre the cushion cover so that the overlap is even on all sides.

Pin one of the open ends together, then sew it closed by machine or hand. Install a zipper, buttons, hooks or Velcro closure on the remaining open end.

Follow the manufacturer’s directions for attaching your chosen closure. Take care to reinforce the closures that will bear weight, like buttons and hooks.

Attach the other half of the closure to the cushion end. Zip or fasten it closed.

Enjoy Your Outdoor Cushion!

You now have a comfortable, weather-resistant cushion customized to your outdoor space! Make a set of matching cushions using the same techniques for a pulled together look.

With proper care, a homemade outdoor cushion can last several seasons outside. When not in use, store the cushion in a covered, dry area or use a cushion cover for extra protection.

Sewing your own outdoor cushion takes a bit of time and effort, but the result is an affordable cushion that’s just right for your needs. Get creative with fun fabric patterns and sizes to enhance your patio, porch or yard.

FAQs About Making Outdoor Cushions

Sewing your own outdoor cushions opens up many possibilities for customization and savings. But you may have some questions before tackling this project. Here are answers to some frequently asked questions.

What is the best fabric for outdoor cushions?

Look for fabric specifically designed for outdoor use, like acrylic, polyester or olefin. Avoid regular cotton, which absorbs moisture. The fabric should have a high thread count and be thick enough to hold batting. Water-resistant coating on the backside is a useful feature.

How do I make cushions last outside?

Use outdoor-rated fabric, thread, batting and closures. When not in use, keep cushions in a cool, dry area instead of leaving them outside. Consider using a cushion cover for extra weather protection and to prolong the life of the cushion.

What can I use instead of batting?

If you can’t find or afford quilt batting, cut up an old foam yoga mat to use as cushion stuffing. Foam sheets from a craft store can also work. Cut them to size and wrap in plastic for moisture protection.

How thick should the batting be?

Choose batting thickness based on the use. For a flat cushion that maintains structure, 2 to 4 inches is sufficient. For a puffy cushion with a soft, pillow-like feel, use 6 inches of batting or more. The thicker the batting, the more cushioning it provides.

What is the best closure for an outdoor cushion?

Zippers are secure and allow you to easily remove the cover for cleaning. Hook and loop tape (Velcro) adheres well when new but may weaken over time. Durable buttons or toggles work for a classic look. Avoid flimsy closures that rely on fabric ties.

Can I use a home sewing machine for outdoor fabric?

You can use a standard home sewing machine, but be sure it can handle thick layers without jamming. Use a longer stitch length to perforate the fabric. Thicker needles and a walking foot attachment can help prevent skipped stitches. Take it slow over bulky seams.

How do I make a cushion cover?

First complete the cushion using the same techniques. Then cut an identical cover piece from fabric, leaving one end open. Sew a zipper,Velcro or buttons onto the opening. Slip the cover over the finished cushion for extra protection and easy laundering.

With the right materials and some sewing skill, you can create durable, stylish outdoor cushions personalized to your space. Refer to this guide when making your own cushions from scratch.

Conclusion

Creating your own outdoor cushions is a great way to save money while sprucing up your outdoor living area. With outdoor-rated fabric, batting, thread and closures, you can make cushions that stand up to the elements for seasons to come. Measure carefully, allow for overlap, and construct a boxed cushion shape for the best durability. Batting provides thickness and structure, while a zipper or other closure keeps the cushion securely on your furniture. With a little time invested sewing your cushions, you’ll reap the rewards in comfort and style.