Making your own outdoor furniture or patio cushions isn't the easiest project around, but if you have some time on your hands and are accomplished with a sewing machine, it will be worth the effort to have custom-made cushions. Make outdoor cushions for your outdoor furniture, or to sit on the ground or deck for lounging. Does this Spark an idea?
Materials
Consider your climate and the use of the cushions when choosing a fabric. If they will be underneath a patio roof or sunshade, they don't need to be as sturdy as if they will be sitting outdoors getting rained on. If you live in a hot climate, cushions will mildew faster, so search for tightly woven, thick synthetics, and avoid nylon and cotton. For a hardy outdoor fabric that is water-resistant, try awning canvas, duck or tent fabric. If your cushions are just sitting under a roofed patio, use whatever upholstery fabric you would like, keeping in mind that some are more easily stained than others if you have children or animals. Threading depends on your fabric, but use a mildew and rot-resistant thread in the thickness you need. Regular-thickness thread will work for plain fabrics, but for heavy canvas or duck, use a thick polyester or nylon thread. If making zip-on covers for cushions, choose plastic zippers to avoid rust. Choose mildew-resistant batting or foam to stuff your cushions with. To sew outdoor cushions, you will need a heavy needle, such as a denim needle, to get through the fabric.
Process
Find a foam cushion form that will fit your furniture. Add batting to the top of the form for fluffier cushions, if desired. Cut your fabric into the cushion shape, leaving 2 extra inches extending on every side. Do this twice for two matching pieces. Use two different fabrics if you want reversible cushions. Sew these two pieces together on three sides, wrong sides out. Insert the foam form, and batting if you like. If you want to make the cover removable, sew a plastic zipper on the fourth side. This will mean carefully folding the edges of the fabric inward and stitching the zipper the length of the side. If not, sew up the fourth side and, if desired, add tie strings at each back corner to tie on to a chair. Make ties with a complimentary color of pre-made cording or ribbon, or make them out of matching fabric by folding a strip a few inches wide into a flat string, and stitching the edges together on one side. Another option is to make button closures, with a decorative button and cording or homemade fabric loop. For more portability, stitch on handy strips of fabric, matching or coordinating, to one side after the cushion is right-side out.
Care
No matter if your cushions are meant to be waterproof or not, they can be ruined by large downpours, so place a hard plastic storage chest nearby to whisk cushions into when it rains heavily. Heavier fabrics are stain-resistant, and can be cleaned with a warm, wet cloth and some dish soap. Lighter fabrics should be unfastened and laundered when soiled. Use sturdy cut foam for the fill instead of adding batting if you want to more easily wash the covers. Or, add a plain inside cover and sew a separate outside cover for removal.
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