Why Choose Custom Outdoor Cushions?

Off-the-shelf outdoor cushions are designed to fit the most common sizes — and if your furniture happens to match, they work fine. But outdoor furniture comes in far more shapes and sizes than the handful of “universal” cushion dimensions available at big-box stores. Custom outdoor cushions solve the problems that universal cushions can’t:

• Perfect fit: No gaps, no overhang, no shifting. Cushions cut to your exact seat dimensions stay put and look clean.
• Fabric choice: Instead of choosing from 5-10 patterns, you pick from hundreds of Sunbrella fabric options — the exact color, pattern, and texture that matches your vision.
• Quality control: Custom cushions use the fill density and construction you specify, not whatever’s cheapest to mass-produce.
• Replacement flexibility: When your furniture frame outlasts its original cushions (which it will), custom replacements restore it to like-new condition at a fraction of the cost of new furniture.

At Carolina Patio Furniture, we’ve been manufacturing custom outdoor cushions in Charlotte since 1979. As a factory-direct operation, we cut, sew, and fill every cushion in-house — there’s no middleman markup.

Sunbrella Fabric: The Gold Standard

Sunbrella is the most trusted name in outdoor fabric, and for good reason. Made from solution-dyed acrylic fibers, Sunbrella fabric is engineered for outdoor performance:

• Fade-resistant: The color is part of the fiber itself (solution-dyed), not applied to the surface. This means the color goes all the way through and resists fading even after years of sun exposure.
• Water-repellent: The fabric repels water without feeling stiff or plastic-like. Rain beads up and rolls off.
• Mildew-resistant: The acrylic fibers don’t absorb water, which eliminates the moisture that mildew needs to grow.
• Easy to clean: Most stains come out with soap and water. For tougher stains, Sunbrella fabrics can handle diluted bleach without damage.
• 10-year warranty: Sunbrella backs their fabric with a 10-year limited warranty against fading and loss of strength.

Sunbrella Color and Pattern Options

The current Sunbrella collection includes over 500 outdoor-rated fabrics organized into categories:

• Solids: Clean, single-color fabrics in everything from bright poolside blues to neutral taupes and grays
• Stripes: Classic nautical stripes, wide cabana stripes, and subtle ticking patterns
• Textures: Woven patterns that add visual depth — herringbone, basketweave, and linen-look options
• Patterns: Florals, geometrics, tropicals, and ikats for statement-making cushions
• Performance blends: Sunbrella + polyester blends that feel even softer while maintaining outdoor durability

Choosing a fabric from a website or catalog can be tricky — colors look different on screens than in person. We keep current Sunbrella swatch books at our Charlotte showroom so you can see and feel the actual fabric before ordering.

PVC Fabric: The Low-Maintenance Alternative

For customers who want truly zero-maintenance cushions, PVC-coated mesh fabric is an alternative worth considering. This material:

• Dries almost instantly — no water absorption at all
• Cleans with just a hose rinse
• Won’t mold, mildew, or stain
• Holds up to pool chemicals and salt air

The trade-off is a different feel — PVC mesh is firmer than Sunbrella fabric and has fewer color/pattern options. It’s an excellent choice for pool-adjacent furniture and high-splash areas.

How to Measure for Custom Cushions

Accurate measurements are essential for custom cushions. Here’s how to measure your furniture:

Seat Cushions

1. Width: Measure the front edge of the seat from left to right, inside the armrests if applicable
2. Depth: Measure from the front edge of the seat to the back
3. Thickness: Decide on your desired cushion thickness (standard is 5 inches for deep seating, 3 inches for dining)
4. Shape: Note if the seat is square, trapezoidal (wider in front than back), or curved. For non-rectangular seats, measure the front width, back width, and depth.

Back Cushions

1. Width: Measure across the back opening at its widest point
2. Height: Measure from the seat surface to the top of the back frame (or desired cushion height)
3. Thickness: Typically 4-5 inches for deep seating backs

Pro Tips

• Measure the furniture frame, not old cushions — cushions compress and deform over time
• If your old cushions fit well when new, measuring them is fine — just note any compression
• For complex shapes (curved, L-shaped, wedge), make a paper template and bring it in
• When in doubt, bring a photo of your furniture to our showroom — we’ve measured thousands of sets and can usually identify your model

Cushion Fill Options

High-Density Foam

The standard for quality outdoor cushions. A 1.8-2.0 lb density foam core provides firm support that maintains its shape over years. This is what we use in our standard deep seating cushions. It’s comfortable, supportive, and rebounds to its original shape after sitting.

Quick-Dry Foam

Open-cell foam with channels that allow water to drain through rather than being absorbed. Quick-dry foam can dry in as little as 2-4 hours after rain (compared to 1-2 days for closed-cell foam). This is our recommended fill for uncovered furniture that gets regular rain exposure.

Dacron-Wrapped Foam

A polyester fiber wrap around the foam core adds a softer, more pillowy feel and helps cushions maintain a plump appearance. We recommend Dacron wrapping for back cushions especially, where a softer feel enhances comfort.

Why Buy Custom Cushions from a Manufacturer

There are plenty of online custom cushion services, so why choose a local manufacturer like Carolina Patio Furniture?

• Factory-direct pricing: No retailer markup, no shipping from a distant factory. Our cushions are made right here in Charlotte.
• See before you buy: Touch fabric swatches, feel foam densities, and see finished cushion examples before ordering.
• Expert fitting: We can measure your furniture on-site or from detailed photos. Four decades of experience means we’ve seen virtually every frame style made.
• Fast turnaround: Because we manufacture in-house, we can typically complete custom cushion orders faster than online services that outsource production.
• Adjustments: If something isn’t perfect, we’re right here to make it right. No shipping cushions back and forth across the country.

Caring for Your Outdoor Cushions

Weekly Maintenance

Brush off leaves and debris. Flip cushions occasionally to distribute wear evenly. After rain, stand cushions on edge to promote drainage.

Monthly Cleaning

Mix 1/4 cup mild dish soap per gallon of warm water. Apply with a soft brush, scrub gently, and rinse thoroughly with a hose. Allow to dry completely before replacing on furniture.

Stain Removal

For food stains, bird droppings, tree sap, or mildew spots: apply a solution of 1 cup bleach + 1/4 cup mild soap per gallon of water. Let sit 15 minutes, then scrub and rinse. Sunbrella fabric handles this without fading — that’s part of what makes it the industry standard.

Off-Season Storage

If you won’t be using your outdoor furniture for an extended period (winter months), store cushions in a dry indoor location — a garage, shed, or storage bin. Clean before storing to prevent stain setting and mildew. Avoid plastic bags, which trap moisture — use breathable storage bags instead.

Frequently Asked Questions

How much do custom outdoor cushions cost?

Custom cushion pricing depends on size, foam density, and fabric selection. A standard deep seating seat cushion in Sunbrella fabric typically runs $80-$200, while a full set (seat + back) ranges from $150-$350. Premium Sunbrella fabrics and extra-thick foam add to the cost. Our factory-direct pricing is typically 20-40% below comparable online custom cushion services.

How long do Sunbrella cushions last?

With normal use and basic care, Sunbrella cushions typically last 5-8 years outdoors before showing significant wear. The fabric often outlasts the foam — if your covers are still in good shape but the cushions feel flat, we can re-fill with new foam and reuse your existing covers.

Can I use indoor fabric for outdoor cushions?

We strongly advise against it. Indoor fabrics lack UV stabilizers (they’ll fade within months), water resistance (they’ll mildew), and the structural strength to handle outdoor conditions. The cost difference between indoor and Sunbrella fabric is modest compared to the difference in longevity.

What if I can’t find the right Sunbrella color?

With 500+ options, it’s rare that we can’t find a match. But if your perfect color truly doesn’t exist in the current Sunbrella line, we also carry fabrics from Outdura and other performance outdoor fabric brands. Come see the full swatch library at our showroom — sometimes the right color is one you didn’t know existed.

Visit Our Showroom to Start Your Custom Cushion Order

The easiest way to order custom outdoor cushions is to visit our Charlotte showroom with your measurements (or your old cushions). Browse the full Sunbrella fabric library, feel the foam options, and we’ll give you an on-the-spot quote. Most orders are ready within 2-3 weeks.

Visit Carolina Patio Furniture in Charlotte, NC. Factory-direct custom cushions since 1979 — no middleman, no markup, no surprises.