Custom Cushions and Foam

Custom cushions built for hospitality, marine, and outdoor.

Large-scale custom cushion production and commercial foam for hotels, resorts, vacation rentals, and marine interiors. Replacement seat cushions, decorative pillows, outdoor pool cushions, and specialty foam cut to any dimension. Fire-rated and built to survive daily use.

Any SizeCut to Spec
COMFabric Policy
Marineand Outdoor Grade
Fire-RatedTB117 Compliant
Custom cushions built for hospitality, marine, and outdoor.
Product Range

Every cushion and foam configuration, cut to your spec.

From replacement seat cushions to outdoor pool cushions to decorative pillows. Every cushion cut and sewn to your exact dimensions, fabric, and foam density. Indoor, outdoor, and marine applications.

How We Build

Commercial cushion construction. Cut to last.

Cushions take constant compression, cleaning, and in outdoor settings, weather. Our foam densities and fabric attachment are engineered for the application, whether guestroom, poolside, or marine.

01 · Foam

Application-specific foam density

High-density commercial foam matched to the application. Firm seat foam for daily use, quick-dry open-cell foam for outdoor, and specialty densities for marine. Engineered to hold shape under constant compression.

02 · Fabric

Indoor, outdoor, and marine fabric

Commercial indoor fabric, weather-resistant outdoor fabric, and marine-grade materials with UV and salt resistance. Sunbrella and marine vinyl options. COM accepted or select from our library.

03 · Construction

Reinforced cut and sew

Double-stitched seams, boxed corners, and zippered covers for cleaning and foam replacement. Marine-grade thread and UV-resistant welting on outdoor cushions. Cut to exact dimensions for a precise fit.

04 · Compliance

Fire and safety compliance

California TB117-2013 compliant foam and construction for indoor applications. CAL-133 upgrades available. FR fabric options meet NFPA 701. Compliance certificates ship with every indoor order.

Your dimensions. <em>Your foam. Your fabric.</em>
Every Cushion Custom

Your dimensions. Your foam. Your fabric.

Send us your cushion dimensions or a pattern. We cut foam to your exact size, select the right density for the application, and sew in your brand-approved fabric. Indoor, outdoor, or marine.

  • Cut to your dimensions Send measurements or a pattern. We cut foam to your exact size and shape.
  • Application-matched foam Firm seat, quick-dry outdoor, or marine density selected for your use.
  • COM fabric accepted Ship your brand-approved fabric, or select from our indoor and outdoor library.
  • Zippered for maintenance Removable zippered covers for cleaning and future foam replacement.
Request Fabric Samples
Case Study · Resort Pool Deck

Johnson recut every cushion for our pool deck, 200 chaise lounges and 40 daybeds. Two full seasons of sun and chlorine and they still look new. We stopped replacing cushions every year.

Facilities Director Coastal Resort
Common Questions

Custom cushion procurement, answered.

The technical questions procurement and facilities teams ask before a cushion order. If your question is not answered here, we will respond within one business day.

Can Johnson replace cushions for our existing furniture?

Yes. Custom replacement cushions are one of our core products. Send us the dimensions of your existing cushions or the furniture pattern, and we cut new foam and sew new covers to match exactly. Replacement cushions restore worn furniture at a fraction of the cost of full replacement, extending the life of quality frames.

What is the lead time for custom cushion orders?

Standard lead time is 4 to 6 weeks from dimensions and fabric approval to shipment for typical orders. Large-volume orders such as full pool decks or property-wide cushion replacement may require 6 to 10 weeks. Rush production is available for urgent needs with an expedite fee.

What foam density should I choose for hotel cushions?

Foam density depends on the application. Johnson recommends high-density firm foam for daily-use seat cushions, quick-dry open-cell foam for outdoor and pool cushions, and specialty marine-grade foam for yacht and waterfront use. We match the density to your application so cushions hold their shape under constant use.

Do you make outdoor and pool cushions that survive weather?

Yes. Johnson builds outdoor and pool cushions using quick-dry open-cell foam, marine-grade UV-resistant fabric (Sunbrella, marine vinyl), and reinforced weather-resistant construction. Marine-grade thread and UV-resistant welting ensure cushions survive sun, rain, and chlorine exposure season after season.

What is COM fabric policy for cushions?

COM (Customer's Own Material) means you ship your brand-approved fabric to our facility, and we cut and sew cushions to your exact specifications. Alternatively, select from our in-house library of indoor, outdoor, and marine-grade fabrics. Indoor orders include fire safety certification.

Do cushion covers come off for cleaning?

Yes. Johnson cushions are built with removable zippered covers for easy cleaning and future foam replacement. This extends cushion life and simplifies housekeeping maintenance. Covers can be laundered or spot-cleaned depending on the fabric.

Can Johnson supply bulk foam cut to custom shapes?

Yes. Johnson supplies commercial foam in any density, cut to any shape. This includes mattress foam, seat foam, bolster foam, and specialty cuts for renovation and repair projects. Send us your specifications and we cut foam to your exact requirements.

Do Johnson indoor cushions meet fire safety compliance?

Yes. Johnson indoor cushions are manufactured to California TB117-2013 fire safety standards as standard, with CAL-133 upgrades available for public space installations. FR fabric options meet NFPA 701. Fire safety certificates ship with every indoor commercial order.

Ready to Recushion

Every cushion order starts with a dimension.

Send us your cushion dimensions, quantity, application (indoor, outdoor, or marine), and target lead time. We will respond within one business day with a quote, fabric samples, and a realistic delivery date.

Visit the Factory

Come see where it is made.

Every piece is built by hand in our Myrtle Beach facility. Trade partners and purchasing teams are welcome to tour the floor and inspect construction in person.

Get in Touch
Address1010B 8th Ave North
Myrtle Beach, SC 29577
HoursMonday to Friday
8 AM to 5 PM ET

Factory tours by appointment for trade partners and purchasing teams.