What you need to sew a seat cushion

A seat cushion is a fabric envelope stuffed with batting or foam. You sew three sides closed, stuff it, then sew the fourth side shut. The whole project takes two to four hours depending on cushion size and your sewing speed. You do not need a sewing machine — hand-sewing works, though it takes longer.

Gather these materials before you start: two pieces of fabric cut to the same size (usually 16 by 16 inches for a standard chair cushion), batting or polyester fiberfill for stuffing, thread that matches your fabric, a needle or sewing machine, scissors, pins, and a measuring tape. If you want a firmer cushion, use a pre-cut foam pad instead of loose fiberfill. A zipper foot attachment for your machine makes adding a zipper easier, though it is not required.

Key Takeaways

  • Cut two identical fabric pieces, pin them with the right sides facing each other, and sew three sides with a half-inch seam allowance.
  • Turn the cushion right-side out through the opening, press the seams flat, and stuff it firmly with batting or fiberfill until it holds its shape.
  • Fold the raw edges of the opening inward and sew them closed by hand using a ladder stitch, which hides the seam inside the fold.
  • A zipper sewn into one side lets you remove and wash the cover later, though it adds 30 minutes to the project.

Cutting and pinning your fabric pieces

Start by deciding your cushion size. A standard chair seat is 16 by 16 inches; a bench cushion might be 18 by 48 inches. Add one inch to each dimension to account for seam allowance — so a 16-inch cushion needs two pieces cut at 17 by 17 inches. Lay your fabric flat, measure carefully with a tape measure, and mark the corners with a pencil or fabric pen before cutting.

Place the two fabric pieces on top of each other with the right sides facing each other — the pretty side of the fabric should be touching the pretty side of the other piece. Pin around all four edges, spacing pins about 3 inches apart. The pins hold the layers together while you sew and prevent them from shifting. Leave one side unpinned for now; this is where you will turn the cushion right-side out and stuff it later.

Sewing three sides with a machine or by hand

If you are using a sewing machine, set it to a straight stitch with medium tension. Start at one corner of a pinned side and sew slowly, keeping the needle half an inch away from the fabric edge. This half-inch gap is your seam allowance. Sew all the way to the next corner, then pivot the needle and turn the fabric 90 degrees. Continue around three sides until you reach the end of the third side. Remove pins as you approach them.

If you are hand-sewing, thread your needle and tie a knot at the end. Push the needle through both layers of fabric half an inch from the edge, then bring it back out a quarter inch forward. Push it back in and repeat this running stitch all the way around three sides. Your stitches do not need to be perfect — they will be hidden inside the cushion. Aim for stitches roughly the same size, about a quarter inch long, and keep them half an inch from the edge.

Turning the cushion right-side out and stuffing it

Once three sides are sewn, reach through the open fourth side and grab the fabric from the inside. Pull gently until the cushion turns inside-out, bringing the right sides of the fabric to the outside. Push the corners out fully so they are sharp and square. Lay the cushion flat and press the seams with an iron on low heat, or run your fingers along the seams to flatten them.

Now stuff the cushion. If you are using loose fiberfill, pull it apart into small clumps and push it into the corners first, then fill the rest. Pack it firmly so the cushion holds its shape and does not feel floppy, but not so tight that the seams strain. If you are using a foam pad, slide it through the opening. You should be able to close your hand around the stuffed cushion and feel resistance, but your fingers should not sink in deeply.

Closing the opening with a ladder stitch

Fold the raw edges of the opening inward by half an inch and press them flat with your fingers or an iron. Pin the opening closed. Thread a needle and tie a knot, then bring the needle up through the fold on one side of the opening — the knot will stay hidden inside the fold.

Push the needle straight across into the fold on the opposite side and slide it along inside the fold for about half an inch, then bring it back out. Go back to the first side and repeat: push in, slide half an inch, come out. This is called a ladder stitch because the thread runs back and forth like the rungs of a ladder, hidden inside the fold. Every few stitches, pull the thread gently to close the gap. When you reach the end, tie a knot inside the fold and trim the thread. The seam will be nearly invisible.

Adding a zipper for a removable cover

If you want to wash the cushion cover later, sew a zipper into one side before stuffing. After cutting and pinning your fabric pieces, open the zipper and lay it face-down along one of the pinned sides, with the zipper tape aligned with the seam line. Pin the zipper in place, then use a zipper foot on your sewing machine to sew it down. Flip the cushion over and sew the other side of the zipper tape the same way.

Once the zipper is sewn in, sew the other three sides as normal. When you turn the cushion right-side out, open the zipper fully before pulling — this gives you more room to reach inside and stuff it. After stuffing, zip it closed. A zipper adds about 30 minutes to the project but means you can remove the cover to wash it without opening a seam.

Finishing touches and care

Once the opening is closed, your cushion is complete. Press it again with an iron to smooth any wrinkles. If you used fiberfill, the cushion will soften slightly over time as the filling settles. Fluff it occasionally by squeezing and kneading it to redistribute the stuffing evenly.

To clean a cushion without a zipper, spot-clean the cover with a damp cloth and mild soap. If the cover needs a full wash, you will have to open one seam, remove the stuffing, wash and dry the cover, then sew it closed again. This is why a zipper is worth the extra time if the cushion will see heavy use. Store cushions in a dry place away from direct sunlight to prevent fading.

Frequently Asked Questions

What fabric works best for a seat cushion?

Cotton, linen, and canvas are durable and straightforward to sew. Avoid stretchy fabrics like knit or jersey unless you are experienced — they shift while sewing and are harder to control. For a cushion that will sit on a chair, choose a medium-weight fabric that will not show wear quickly. Upholstery fabric is thicker and lasts longer than quilting cotton.

Can I use old clothing or sheets instead of buying new fabric?

Yes. Old cotton sheets, jeans, or t-shirt fabric all work. Wash and dry them first so they do not shrink after you sew the cushion. Be aware that thin fabric may show the outline of the stuffing, so use two layers or back it with a second piece of fabric for a smoother look.

How much fiberfill do I need?

A 16-by-16-inch cushion needs roughly one to two pounds of fiberfill, depending on how firm you want it. A 18-by-48-inch bench cushion needs three to four pounds. Buy a little extra — it is inexpensive and you can save leftovers for future projects.

What if my seams are uneven or my stitches show?

Uneven seams are normal for a first cushion. They do not affect how the cushion works. If stitches show on the outside, you can cover them with trim, ribbon, or piping sewn along the edge. This also reinforces the seams and makes the cushion look more finished.

Can I make a cushion without a sewing machine?

Yes. Hand-sewing takes longer — usually four to six hours instead of two to three — but the result is the same. Use a running stitch or a backstitch, which is stronger. Tie off your thread every foot or so to prevent a long thread from breaking and unraveling the whole seam.