Making Outdoor Seat Cushions

Making Outdoor Seat Cushions: A Comprehensive Guide

Outdoor seat cushions can significantly enhance the comfort and aesthetic appeal of patios, decks, and other outdoor living spaces. However, commercially available cushions can be expensive, and may not always perfectly match the desired size, style, or fabric. Creating custom outdoor seat cushions offers a cost-effective solution with the added benefit of personalization. This article provides a comprehensive guide to making durable and attractive outdoor seat cushions.

Selecting Appropriate Materials

The longevity and performance of outdoor seat cushions are heavily dependent on the materials chosen. Opting for weather-resistant fabrics and fillings that can withstand moisture, sunlight, and temperature fluctuations is crucial. The key considerations are fabric choice, filling material, and thread selection.

Fabric Selection:

The fabric used for outdoor cushions should be specifically designed for outdoor use. These fabrics are typically treated to resist fading, mildew, and water damage. Popular choices include:

Solution-dyed acrylic fabrics:

These fabrics are known for their excellent fade resistance and durability. The color is locked into the fiber itself, preventing it from washing out or fading due to sun exposure. They are also water-repellent and easy to clean.

Polyester fabrics:

Outdoor polyester fabrics are often treated with a water-repellent finish. They are more budget-friendly than solution-dyed acrylic, but may not be as fade-resistant over the long term. However, newer high-performance polyester fabrics are becoming increasingly durable.

Olefin fabrics:

Olefin is a synthetic fiber that is naturally resistant to moisture, mildew, and stains. It is also relatively lightweight and can be a good option for cushions that need to be easily moved. Olefin is a generally cost effective option between polyester and dolution dyed acrylic.

Before selecting a fabric, verify its UV resistance rating and water repellency specifications. Higher UV resistance ratings indicate better protection against fading. A water-repellent finish will help prevent water from soaking into the cushion's filling. Also consider the texture and pattern of the fabric to complement the outdoor space.

Filling Material:

The filling material determines the comfort and support provided by the cushion. It also affects the cushion's water resistance and drying time. Common filling options include:

Polyester fiberfill:

This is a widely used and relatively inexpensive filling material. It is lightweight, resilient, and dries quickly, which is important for outdoor cushions. However, it can compress over time, requiring replacement or re-fluffing.

Polyurethane foam:

Foam is a more supportive option than fiberfill and provides better cushioning. It is available in various densities, with higher densities offering firmer support. Outdoor-grade foam is treated to resist mildew and moisture.

Dryfast foam:

This type of foam is specifically designed for outdoor use. It has an open-cell structure that allows water to drain quickly, preventing mildew and mold growth. Dryfast foam is more expensive than standard foam but offers superior performance in wet conditions.

Shredded Foam:

Recycled or new shredded foam can be used as a filling. It is often a more sustainable choice and provides good support and cushioning. Make sure any shredded foam used for outdoors cushions is mold and mildew resistant.

When choosing a filling material, consider the desired level of support, the cushion's exposure to moisture, and the budget. For areas with frequent rainfall, dryfast foam is often the best choice, despite its higher cost.

Thread Selection:

The thread used to sew the cushion should be durable and weather-resistant. Polyester or nylon threads specifically designed for outdoor use are recommended. These threads are less likely to rot or break down when exposed to sunlight and moisture. It is crucial to select a thread color that matches or complements the fabric for a professional finish.

Consider using UV resistant thread for prolonged sun exposure of your outdoor cushions. UV can break down even the strongest thread over time.

Constructing the Cushion Cover

Creating a well-fitting and durable cushion cover requires accurate measurements, precise cutting, and careful sewing. The following steps outline the process of constructing a standard box cushion cover.

Measuring and Cutting the Fabric:

Begin by measuring the dimensions of the seat or furniture where the cushion will be placed. Add seam allowances to all measurements. A standard seam allowance is 1/2 inch (1.3 cm), but this can be adjusted based on the thickness of the fabric and the desired seam strength. Cut the fabric pieces according to the following pattern:

Top and Bottom Panels:

Cut two rectangular pieces of fabric with the desired length and width of the cushion, plus seam allowances on all sides.

Side Panel (Welt):

Cut a strip of fabric with a width equal to the desired thickness of the cushion (the box height), plus seam allowances on both edges. The length of the strip should be equal to the perimeter of the top panel, plus seam allowances.

Accurate cutting is essential for a well-fitting cushion. Use a rotary cutter, ruler, and cutting mat for precise cuts. Mark all cutting lines clearly on the fabric before cutting.

Sewing the Side Panel:

Fold the side panel in half lengthwise, wrong sides together, and press. This creates a crease that will serve as a guide when sewing the corners. Unfold the side panel and sew the short ends together, right sides together, to form a continuous loop. Press the seam open.

Attaching the Side Panel to the Top Panel:

Pin the side panel to the top panel, right sides together, matching the raw edges. Start pinning at one corner and work around the top panel, easing the side panel as needed. Sew the side panel to the top panel, using the designated seam allowance. Clip the corners to reduce bulk and allow for a smoother curve.

Attaching the Bottom Panel:

Repeat the process of attaching the side panel to the bottom panel, leaving an opening of approximately 12-18 inches (30-45 cm) along one side for inserting the filling. This opening can be closed with a zipper, snaps, or Velcro.

Turning and Finishing the Cover:

Turn the cushion cover right side out and press the seams. This will give the cover a professional and tailored appearance. If using a zipper, install it along the opening. Alternatively, attach snaps or Velcro along the opening, ensuring a secure closure.

Sewing Techniques and Tips:

Use a durable stitch, such as a straight stitch with a short stitch length, to ensure the seams hold up under repeated use. Reinforce the corners of the cushion with additional stitching for added durability. When sewing around curves, clip the seam allowance to allow the fabric to lie flat.

Inserting the Filling and Finishing Touches

The final step involves inserting the chosen filling material into the cushion cover and securing the opening. Additional embellishments, such as buttons or piping, can be added to enhance the cushion's aesthetic appeal.

Inserting the Filling:

Carefully insert the filling material into the cushion cover, ensuring that it is evenly distributed. For fiberfill, fluff the filling before inserting it to prevent clumping. For foam, cut the foam to the appropriate size and shape before inserting it into the cover. If using shredded foam, evenly distribute to prevent clumping or unevenness.

Closing the Opening:

Once the cushion is filled to the desired firmness, close the opening. If using a zipper, simply zip it closed. If using snaps or Velcro, align the fasteners and press them together to secure the closure.

Adding Embellishments (Optional):

Buttons or decorative piping can be added to the cushion for added flair. Buttons can be sewn onto the top and bottom panels of the cushion, creating a tufted effect. Piping can be sewn along the edges of the cushion, adding a touch of elegance and sophistication.

Ongoing Maintenance:

To prolong the life of outdoor seat cushions, regular maintenance is important. This includes:

Cleaning:

Periodically clean the cushions with a mild soap and water solution. Use a soft brush to remove dirt and debris. Rinse thoroughly and allow the cushions to air dry completely before storing them.

Storage:

When not in use, store the cushions in a dry, sheltered location, such as a shed or garage. This will protect them from the elements and prevent mildew and mold growth.

Re-fluffing or Replacement:

Over time, the filling material may compress, reducing the cushion's comfort and support. Re-fluff the filling periodically, or replace it entirely if necessary.

By following these guidelines, it is possible to create custom outdoor seat cushions that are both durable and visually appealing. The selection of appropriate materials, careful construction techniques, and regular maintenance will ensure that the cushions provide years of comfortable seating in any outdoor space.