What You Need to Make a Bean Bag Chair

A bean bag chair is a fabric shell filled with polystyrene beads or shredded foam. You sew two pieces of fabric together, leave an opening for filling, pour in the beads, then stitch the opening closed. The whole project takes a weekend and costs between $30 and $80 depending on fabric choice and fill material.

You will need: two pieces of fabric (canvas, denim, or upholstery fabric work best), a sewing machine, thread that matches your fabric, scissors, a measuring tape, pins, and a bag of polystyrene beads or shredded foam fill. A pattern is optional—you can cut your own shape freehand or read a pattern from a sewing site.

The fabric should be sturdy enough to hold weight without tearing. Lightweight cotton will split under the pressure of the beads. Canvas, denim, or upholstery-weight fabric lasts longer. You will need roughly 2 to 3 yards of fabric depending on the size chair you want.

Key Takeaways

  • Cut two identical fabric pieces, pin them together with the right sides facing inward, and sew three sides closed with a straight stitch using a 1/2-inch seam allowance.
  • Leave one side open, turn the fabric right-side-out through that opening, and press the seams flat with an iron.
  • Fill the chair through the opening with polystyrene beads or shredded foam until it reaches the firmness you want, then fold the raw edges inward and sew the opening closed by hand or machine.
  • Use a needle and thread for hand-stitching the final seam, or fold the edges under and machine-stitch if you want a faster finish.
  • Polystyrene beads are cheaper and lighter than foam, but they compress over time and may need topping off every year or two.

Cutting and Pinning Your Fabric Pieces

Decide on the shape and size of your chair. A common size is roughly 3 feet wide by 4 feet tall when finished. You can make it smaller or larger, but remember that bigger chairs need more fill and more fabric. Sketch the shape on paper first—a straightforward rounded rectangle or teardrop shape works well and is easier to sew than sharp corners.

Fold your fabric in half, right sides together (the pretty side facing inward). Pin your pattern to the folded fabric and cut both layers at once. This gives you two identical pieces without having to measure twice. If you are not using a pattern, measure and mark your shape with chalk or a fabric pen, then cut carefully with sharp scissors.

Lay both pieces flat on a table with right sides facing each other. Pin around three of the four sides, spacing pins about 4 inches apart. Leave one entire side unpinned—this is where you will turn the fabric right-side-out and pour in the fill later. Make sure the pins go straight through both layers so the fabric does not shift while you sew.

Sewing the Three Closed Sides

Thread your sewing machine with thread that matches your fabric. Set the machine to a straight stitch with a stitch length of 2.5 to 3.0 (medium length). A longer stitch is faster and easier to rip out if you make a mistake; a shorter stitch is stronger but slower.

Start at one corner of a pinned side. Lower the presser foot, backstitch a few stitches to lock the thread, then sew forward along the pinned edge. Keep the fabric edge about 1/2 inch from the needle—this is your seam allowance. Remove pins as you approach them; do not sew over them. When you reach a corner, stop with the needle down, raise the presser foot, pivot the fabric 90 degrees, lower the presser foot, and continue sewing.

Sew all three pinned sides this way. When you reach the end of the third side, backstitch a few stitches to lock the thread, then cut the thread and remove the fabric from the machine. You now have a fabric tube with one open side.

Turning the Fabric Right-Side-Out and Pressing

Reach through the open side and grab the fabric from the inside. Gently pull the fabric through the opening, turning it inside-out as you go. This takes patience—work slowly and do not force it, or you may tear a seam. Once the whole thing is turned right-side-out, the pretty fabric is now on the outside and the seams are hidden inside.

Use your fingers to push the corners and curves outward so the shape is smooth and even. Then lay the chair flat on an ironing board and press it with a warm iron. Pay special attention to the seams—pressing them flat makes the final stitching easier and makes the chair look neater. Let it cool for a minute before moving it.

Filling the Chair with Beads or Foam

Place the open side of the chair over a large bowl or bucket. Pour polystyrene beads or shredded foam through the opening until the chair is as full as you want it. A typical large bean bag needs 40 to 60 pounds of beads. Start with less than you think you need—you can always add more, but you cannot easily remove it.

As you fill, squeeze the chair to feel how firm it is getting. A firmer chair feels more like a seat; a looser one is more like a nest. Most people prefer a firmness somewhere in the middle. Stop filling when the chair feels right to you, then fold the raw fabric edges inward about 1/2 inch on both sides of the opening.

Polystyrene beads are the most common and cheapest fill. They are lightweight and compress slightly, making the chair conform to your body. Shredded foam is denser, firmer, and lasts longer without compressing, but it costs more and weighs more. Both are available online or at fabric stores.

Closing the Opening by Hand or Machine

You have two options for closing the final opening: hand-stitching or machine-stitching. Hand-stitching is slower but gives you more control and is less likely to trap beads in the seam. Machine-stitching is faster but requires care to keep beads away from the needle.

For hand-stitching, thread a needle with thread that matches your fabric. Tie a knot at the end. Starting at one corner of the opening, push the needle through the folded edge of one side, then through the folded edge of the other side, working your way along the opening. Use a ladder stitch (also called an invisible stitch) if you want the seam to be nearly invisible: push the needle into the fold of one side, slide it along inside the fold for about 1/4 inch, then push it out and across to the other side, slide it along that fold, and repeat. This creates a seam that closes from the inside and is hard to see from the outside.

For machine-stitching, fold both raw edges inward 1/2 inch and pin them together. Sew slowly along the opening with a straight stitch, keeping beads pushed away from the needle as you go. This is faster than hand-stitching but requires a steady hand and patience.

Caring for Your Bean Bag Chair

Polystyrene beads compress over time as they are sat on. After a year or two, you may notice the chair feels flatter. You can open a small section of the seam, pour in more beads, and stitch it closed again. Some people make a hidden zipper opening for this reason, though it adds complexity to the sewing.

If you spill something on the chair, spot-clean the fabric with a damp cloth and mild soap. Do not machine-wash the whole chair—the beads will absorb water and take weeks to dry. If the fabric tears, you can patch it from the inside by sewing a piece of matching fabric over the hole, or from the outside if you do not mind the patch being visible.

Bean bag chairs last longer if they are not sat on constantly or dragged across rough floors. A chair in a bedroom or reading nook will last years; one in a high-traffic living room may need refilling sooner.

Frequently Asked Questions

Can I use a sewing machine for the whole project, including closing the opening?

Yes. Machine-stitching the final opening is faster than hand-stitching. Push the beads away from the opening as you sew, work slowly, and keep the fabric edges folded inward so the needle does not catch any beads. If a bead does get caught, stop, remove it, and continue.

What fabric should I use if I want the chair to be washable?

Use a removable cover instead of sewing the fabric directly to the fill. Sew two fabric pieces together, fill it, close it, then sew a larger outer cover around it with a zipper opening. This way you can unzip and wash the outer cover while the inner bag stays dry. It is more work but much easier to clean.

How much does it cost to make a bean bag chair?

Fabric costs $10 to $30 depending on whether you choose basic canvas or nicer upholstery material. Polystyrene beads cost $15 to $40 for a 100-pound bag, which is enough for one large chair or two medium ones. Thread and other supplies cost a few dollars. Total is usually $30 to $80 for one chair.

What if I do not have a sewing machine?

You can hand-stitch the entire chair using a needle and thread, but it takes much longer—expect 6 to 8 hours instead of 1 to 2. Use a running stitch or backstitch for strength. A sewing machine makes the project much faster and creates stronger seams, but it is not required.

Can I make a bean bag chair without a pattern?

Yes. Sketch the shape you want on paper, measure it, then mark it on your folded fabric with chalk or a fabric pen and cut it out. straightforward shapes like rounded rectangles or teardrops are easier to sew than complex ones. You do not need a commercial pattern unless you want a specific design.