Cushions may seem simple, but there’s a lot that goes into making them comfortable, durable, and stylish. Here's a straightforward overview of how cushions are made — from filling to finish.
1. It All Starts With the Filling
Before anything else, a cushion needs an inner filling. Common types include:
- Feather or down: Soft and luxurious, though less suitable for allergy sufferers.
- Polyester fibre: A popular, affordable, and easy-care option.
- Foam or memory foam: Offers structure and support, often used in seat or floor cushions.
- Traditional options: Materials like straw, wool, or fabric scraps were used historically or in handmade styles.
Common Cushion Sizes and Shapes
Cushions don’t all come in the same size. While 45x45cm is one of the most common for UK homes, cushions also come in rectangular (e.g. 30x50cm), round, bolster-style, or oversized floor versions. The shape and size often depend on the intended use — decorative, supportive, or floor seating.
2. Then Comes the Fabric Cover
The outer cover determines the cushion's look and feel. Common fabrics include cotton, linen, velvet, and upholstery-grade blends. Covers can be plain, patterned, textured, or embroidered, depending on the intended use and style.
3. Time to Cut and Sew
- The fabric is cut to size, typically in square or rectangular shapes.
- Edges are sewn together, leaving space for a zip or envelope-style opening if the cover is removable.
- Alternatively, the cover may be fully sewn shut if it’s not designed to be removed.
Thinking of making your own cushion cover with a zip? You can follow this step-by-step guide.
4. Insert the Filling
Once the cover is ready, the cushion insert is placed inside. It’s usually recommended to use a slightly larger insert than the cover size to achieve a plump, full appearance.
5. Final Adjustments and Quality Check
For a more technical look at how soft furnishings are manufactured at scale, you can read this detailed guide on how pillows are made.
The completed cushion is checked for shape, seams, symmetry, and closure function. Any unevenness is corrected by reshaping or refilling, and the cushion is fluffed or pressed to achieve a neat finish.
What Makes a Cushion Durable?
A well-made cushion should hold its shape, withstand everyday use, and keep looking good over time. Durability often comes down to:
- High-quality fabric with a tight weave
- Strong seams and reinforced corners
- A reliable zip or closure
- A well-fitting insert that doesn’t flatten too quickly
Prefer to Skip the DIY?
If you'd rather purchase a professionally made cushion cover, explore our Cushion Covers Collection. Each piece is handmade, unique, and created with quality materials.
