Make Your Own Cushion: Box Cushion With Seamed Corners

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Welcome back to our Cushion Masterclass series! In this blog, we'll teach you how to sew a box cushion the traditional way. The Box Cushion With Seamed Corners has four separate boxing strips that are sewn together and then sewn to the top and bottom plates. This tried-and-true method is more versatile than some other styles because it can be used for square, rectangular and irregularly shaped cushions. Ready to give it a try?

Video Chapters:

Using Calculator & Cutting Plates — 1:20 min.
Cutting Boxing to Size — 3:57 min.
Sewing Zipper Plaque — 7:06 min.
Sewing Boxing Ends Together — 12:50 min.
Making Custom Piping (Optional) — 15:08 min.
Basting & Sewing Boxing to Plate — 19:06 min.
Adding Piping to Plate — 22:48 min.
Sewing Assembly to Final Plate — 26:13 min.
Cutting Foam to Size — 31:06 min.
Inserting Foam in Cover — 32:01 min.
Materials & Tools List — 34:17 min.

Materials List:

Outdura^® Jinga Nautical 54" Upholstery Fabric (#124761)
Lenzip^® #5 Black Continuous Coil Zipper Chain (#124596)
Seamstick 1/4" Basting Tape for Canvas & Upholstery (36 yds.) (#122065)
Tex 70 to 75 Thread from Sailrite
Lenzip^® #5 Black Style A Single Locking Metal Zipper Pull (Coil Chain) (#124600)
Medium 5/32" Welting Cord (#107035)
CushionRite^® Premium Foam — we used Medium (#124234)

Tools List:

Sailrite^® Clear Acrylic Ruler 6" x 24" (#102400)
Chalk Pen White (#123131)
Sailrite^® Tempered Cutting Glass (#121915)
Sailrite^® Edge Cordless Hotknife 18V Package (#122177)
Gingher^® 8" Scissors Right Handed (#19104)
Sailrite^® Ultrafeed^® LSZ Walking Foot Sewing Machine (110V) (#311602)
Sailrite^® Ultrafeed^® Industrial Sewing Table (#120934)
Suisei Magnetic Sewing Guide (#102983)
Multiuse Pins 1-1/2" (250 pack) (#102985)
Sailrite^® Blade Foam Saw V2 with Carrying Case (110V) (#121244)
Straightedge, Marker

If you're a beginner upholsterer looking for a challenge to take your skills to the next level, try this box cushion. The Box Cushion With Seamed Corners is more complex than the Quick and Easy cushion varieties we've shown you in our Cushion Masterclass. It has more steps and takes more time to make. But don't worry — even though it's a more advanced cushion technique, it's still very achievable for new upholsterers!

Features of the Box Cushion

What sets this method apart from the Quick and Easy methods? The main difference is that this box cushion is made from six fabric pieces: four boxing pieces, a top plate and a bottom plate. The boxing pieces have to be sewn to the top and bottom plates, as well as to each other. This cushion also boasts these other features:

Piping can be used for top and/or bottom edges, or neither.
Zipper is installed in back boxing.
Bottom plate can be decorative fabric or cushion underlining fabric.
Flippable if decorative fabric is used on bottom and cushion shape allows.
Pattern matching possible with effort (except side boxing).
Can include a curved or wedged edge.

Box Cushion Seamed Corners 3 — We made a cushion with piping on the top plate. Notice the seam at a corner between two boxing strips.

Ready to test your cushion-making skills? Watch this video now to learn how to make a traditional cushion with boxing that's seamed at the corners. We'll walk you through every step of this intermediate-level cushion upholstery project. You can do it!

Share Your Work

What do you think of this cushion-making technique? Share pictures of your handiwork and let us know how you did in the comments below. This DIY is part of our Cushion Masterclass video series. In this series, you’ll learn how to make a cushion seven different ways. There’s a technique for every use and style preference, so you can customize cushions for any space. How many of the styles will you make?