Custom Patio and Built-In Cushions: A Sizing Guide

Indoor vs outdoor foam

Indoor cushions use closed-cell or HD36 high-density foam at 1.8–2.5 lb density. Outdoor cushions use Dryfast reticulated foam — open-cell, drains by design, won't trap mildew. Wrap with Dacron for crown. The density choice affects both feel and lifespan: 2.5 lb foam outlasts 1.8 lb foam by 5–8 years on a daily-use cushion.

For window seats and built-in benches we usually go 2.0 lb HD36 with 32–35 IFD. That gives the cushion enough firmness to support seated weight without bottoming out, but enough give to feel comfortable for reading or napping. Custom built-in benches in Charlotte and Lake Norman homes often see daily use, so we lean toward higher density even for indoor work.

Fabric choices that last outside

Sunbrella, Outdura, and Tempotest acrylic — solution-dyed, fade-resistant for 5–10 years. Polyester labeled "outdoor" fades in two seasons. Pay for the better fiber upfront and the cushion outlives three rounds of polyester. Sunbrella's fiber technology is solution-dyed at the polymer level, which is why color holds even after years of UV exposure.

For pool deck and lakefront cushions on Lake Wylie and Lake Norman, solution-dyed acrylic plus Dryfast foam plus drain mesh on the bottom is the standard build. Cushions left in the rain dry overnight. Cushions stored in a deck box still need to be dry before stacking, but the same fabric and foam handles a missed afternoon storm without a problem.

Indoor cushions: HD36 high-density foam at 1.8–2.5 lb. Outdoor cushions: Dryfast reticulated foam in solution-dyed acrylic (Sunbrella, Outdura, Tempotest). Measure to the seat opening, not the frame outside.

Measuring tips

The most common cushion mistake is measuring the wrong dimension:

• Width and depth at the seat opening — not the frame outside. The cushion sits inside the frame.
• Height including any desired crown — typically 3–5" for indoor, 3–4" for outdoor.
• Note any cutouts or contours and bring photos. Window seats often have rounded corners or sloped backs.
• Account for fabric thickness — a thick fabric adds 1/8" to each dimension.

For built-in benches, measure each section separately. Most built-ins are not perfectly square, even if they look it. We pattern off your measurements and confirm with a paper template before cutting foam.

Patio furniture cushion replacement

Outdoor patio cushion upholstery is one of our most-requested residential jobs. Most patio cushions fail at the foam (compression) before the fabric does. We rebuild with Dryfast reticulated foam and offer the option to keep the original fabric covers if they are still in good shape, or replace with new Sunbrella in the same or different colorway.

The economics are usually obvious: a set of 6 patio chair cushions runs $300–$600 to rebuild versus $800–$1,500 to replace with new comparable-quality cushions. The rebuild includes pickup and delivery across our standard service area.

Window seats and built-in bench cushions

Built-ins are a custom job by definition. We come out, measure on-site, take photos, and pattern off the actual opening. Window seat cushions usually want a 4–5" crown and a snug fit — not so tight that the cushion can't lift, but tight enough that nothing slides. We finish with welt cord, button tufting, or knife-edge depending on the room style.

For breakfast nooks and bay-window seating we recommend Crypton Home or Sunbrella Living — they look like fabric, feel like fabric, and clean up like vinyl. For formal sunrooms we go performance velvet or wool blends.

Boat and marine cushions

Marine cushions are a different category — see our deeper marine vinyl guide. The short version: marine vinyl, Tenara thread, Dryfast foam, drain holes. Pontoon, runabout, ski boat, and bass boat cushions all follow the same construction logic; only the dimensions and shapes change.

Custom throw pillows and accent cushions

We sew custom throw pillows in any size and shape — from standard 18"x18" up to 36"x36" floor pillows, lumbar shapes, bolster cylinders, and odd shapes for boat helms and built-in nooks. Same fabric as the cushion or coordinating accent.

Pricing and timeline

Indoor cushion rebuild: $80–$200 per cushion depending on size and fabric. Patio cushion rebuild: $50–$150 per cushion. Window seat or built-in bench: $200–$600 depending on size and complexity. Custom-built cushion (foam + fabric + sewing): $150–$400 per cushion. Most projects complete in 7–14 days from measurement.

Specifying for sun-exposed sunrooms and lake homes

Sunrooms across Charlotte, Lake Norman, and Lake Wylie get more direct UV than most exterior patios because the glass concentrates the light. Standard indoor fabric fades visibly within 18 months in this environment. We spec solution-dyed acrylic or Crypton Sunbrella blends for sunrooms — the same materials we use on outdoor patios, just in indoor-friendly weights and patterns.

Lake-house furniture has the additional issue of constant low-grade humidity. Even fully indoor cushions take on moisture over years if the home is not climate-controlled in winter. Closed-cell foam plus performance fabric outlasts standard polyurethane plus traditional upholstery fabric by 2–3x in lake-house applications. Most of our Lake Norman residential customers spec performance fabric on every soft-surface piece in the house for this reason.

Foam, fill, and edge details that matter

The cushion's feel is determined by foam choice, fill wrap, and edge treatment — not just the fabric on top. We choose specs based on intended use:

Closed-cell foam: Standard for outdoor and marine cushions. Doesn't absorb water. Firm feel.

HD36 polyurethane: Standard for indoor cushions. Density tunes lifespan; IFD tunes feel. Wrap with Dacron for crown.

Reticulated Dryfast foam: Open-cell foam engineered to drain. Standard for outdoor seating where rain is a factor.

Down-wrap (Dacron + feather): Premium hand-feel for high-end residential. Requires fluffing.

Edge treatments: Knife-edge (sharp seam at perimeter) reads modern. Box-edge (welted seam) reads traditional. Boxing height affects how the cushion sits in the seat opening — too short and it floats, too tall and it bottoms out.

For built-ins specifically, we usually go box-edge with welt cord matched to the cushion fabric. The welt creates a clean visual line where cushion meets frame and prevents fabric from shifting under daily use.

Patterning, templates, and fitment

For non-rectangular cushions — angled bay window seats, curved breakfast nooks, irregular boat helms — we pattern off the actual space rather than measurement only. Two ways to do this:

• On-site template: We come out, lay paper or thin foam, trace the outline, and take depth measurements. Pattern goes back to the shop.
• Customer template: For customers outside the standard service area or who want to save the visit, we send templating paper and instructions. The customer traces and ships back, often with a few photos for confirmation.

Either approach yields a cushion that fits the actual space rather than a generic rectangle. The fitment difference is usually visible — a templated cushion looks intentional; a measured-only cushion sometimes looks slightly off in a way that customers notice but can't articulate.

Service area at a glance — every town we serve

Our standard service area covers western North Carolina, the Charlotte metro, and the Lake Wylie / Rock Hill side of South Carolina. Specifically:

• Caldwell County (Foothills): Lenoir, Granite Falls, Hudson, Sawmills, Gamewell, Cajah's Mountain, Rhodhiss.
• Catawba County: Hickory, Newton, Long View, Bethlehem, Conover, Maiden.
• Burke County: Morganton, Valdese, Rutherford College, Drexel.
• Mountain communities: Boone, Blowing Rock, Collettsville, Patterson, Globe.
• Charlotte metro: Charlotte, Matthews, Mint Hill, Concord, Kannapolis, Indian Trail, Monroe, Waxhaw.
• Lake Norman: Mooresville, Cornelius, Davidson, Huntersville, Lake Norman.
• South Carolina: Fort Mill SC, Tega Cay SC, Rock Hill SC, Lake Wylie SC.

If your address isn't listed, ask anyway. We have delivered to Asheville, Greensboro, Statesville, and parts of Raleigh on commercial projects, and we have customers in mountain communities who meet us halfway for handoff.

How to start a project with Renew Upholstery

Three ways to start, all of them free:

1. Send photos and a few measurements through the contact page. We respond inside a business day with a written estimate range.
2. Call the shop at (828) 455-3635. We answer during shop hours, Monday through Friday 8 AM – 7 PM.
3. Schedule a free in-person estimate. Free across our standard service area; usually within the same week for the foothills and within 1–2 weeks for the Charlotte and Lake routes.

What helps us help you faster: the front, back, and arm shots of the piece; a photo of the underside if you can flip it; rough measurements (length × depth × height); and a note about what fabric direction you are leaning. The more specific you are, the tighter the initial estimate range we can quote.

Estimates are written, no-obligation, and put numbers on paper so you can compare against any new-furniture or competing-shop quote sitting on your kitchen table. We don't push timelines, run sales follow-up calls, or pressure decisions. Family-owned in Lenoir, NC since 2012; pickup and delivery free across most of the western NC and Charlotte metro service area.

Why customers across western NC and the Charlotte metro choose Renew

The work speaks for itself; what customers tell us also matters. The recurring themes from customer reviews across western NC, the Charlotte metro, and the Lake Wylie communities:

• Honest estimates. If a piece isn't worth rebuilding we say so. We have walked away from work on pieces that didn't justify the rebuild cost.
• Timeline reliability. When we quote 2–4 weeks, the piece comes back in 2–4 weeks. Backorders are communicated immediately, not at the end of the project.
• Materials transparency. The fabric we put on, the foam density we install, and the thread we sew with are all documented on the invoice. Future repair or refresh is straightforward.
• Local presence. Workshop in Lenoir, NC, family-owned since 2012, weekly pickup routes through Hickory, Morganton, Charlotte, Mooresville, and Lake Wylie. We are not a regional broker; we are the shop doing the work.
• Range of capability. Residential, commercial, marine, healthcare, antique, automotive — under one roof, with the same standards across categories.

For the full breakdown of services we offer, see the services overview. For the full geography we cover, see the service area page. Both are kept current as we add capabilities and routes.

Related services across the Renew Upholstery catalog

Our work spans every category of upholstery. If you arrived through this article and need a different service, the most-requested categories are:

• Furniture upholstery: Sofa upholstery, sectional upholstery, chair upholstery, recliner upholstery, dining chair upholstery, antique furniture restoration.
• Residential: window seat cushions, built-in seating, outdoor patio cushions, slipcovers, headboards.
• Commercial: restaurant booths, medical and dental office, church pews, theater seating, hotel furniture, bar stools.
• Marine: boat upholstery, pontoon boat, marine vinyl, marine canvas and covers.
• Automotive: car seat upholstery, classic car upholstery, leather seat repair, headliner repair.
• Repair and restoration: foam replacement, spring repair, frame repair, pet damage repair, water damage, fire damage.
• Custom: custom cushions, leather, vinyl, tufting and decorative, fabric selection consulting.

For the complete service list with pricing ranges and turnaround times, see the services index. For frequently asked questions across categories, see the FAQ page.