The Ultimate Guide to Building Weatherproof Outdoor Cushions

X-HT-300454

Imagine this: It’s a beautiful summer morning. Birds are chirping, the sun is shining, and you have a couple of free hours to yourself. You step onto your patio with a good book and a tall glass of iced tea. As you settle into your chair, you’re met with an unpleasant surprise — the cushion is soaked from last night’s rain! So much for a relaxing morning.

The Ultimate Guide to Building Weatherproof Outdoor Cushions

Why Do Outdoor Cushions Stay Wet?

If your patio cushions absorb water, they likely aren’t made with the right combination of foam and fabric. For cushions that can stay outside year-round — rain, shine and even snow — you need to choose materials wisely. In this guide, we’ll walk you through the best foam, fabric and thread to use so your outdoor cushions stay comfortable and dry no matter the weather.

Step 1: Choose the Right Foam

The foundation of any great outdoor cushion starts with the right foam. We recommend CushionRite® Dry Fast foam for cushions that will be left outside all year long.

Why Dry Fast Foam?

Quick-Drying: Its open-cell structure allows water to pass through easily, meaning no more soggy cushions after a rainstorm.
Mold & Mildew Resistant: Helps prevent unpleasant odors and deterioration.
Customizable: Available in various sizes and thicknesses to fit any cushion design.

Outdoor Cushion Fabric Foam Thread 3 — Water flows right through Dry Fast foam thanks to its blown-out cell walls. This makes it extremely quick-drying for outdoor cushions.

For added softness, wrap your Dry Fast foam in a layer of polyester batting using a spray adhesive (we recommend CushionRite® Foam & Fabric Spray Adhesive, #125476). Batting maintains quick-drying properties while providing extra comfort.

Pro Tip: To make inserting your foam easier, wrap it in silk film, then remove the film once the foam is inside the cushion cover.

Step 2: Pick Durable Outdoor Fabric

Outdoor cushions need fabric that withstands the elements while remaining stylish. We recommend performance upholstery fabrics known for their durability, UV resistance and easy maintenance.

Best Outdoor Fabric Brands:

Outdura® Upholstery
Sunbrella® Upholstery
SunRite™
Covington

Outdoor Cushion Fabric Foam Thread 4 — These performance fabrics make great all-season outdoor cushions.

These fabrics are solution-dyed, meaning the color penetrates each yarn for long-lasting vibrancy. They are also water-resistant and simple to clean.

If style is your priority, consider Solarium, Richloom and Tommy Bahama®. These brands offer detailed patterns but may not last as long as performance fabrics.

Enhance Water Drainage:

To improve water drainage and quick-drying even further, you can also add a Phifertex® mesh fabric or cushion underlining to the bottom of your cushion. Alternatively, install vent grommets or a mesh zipper plaque to allow for better airflow.

Outdoor Cushion Fabric Foam Thread 5 — Printed fabrics add lots of color and pattern to outdoor cushions, though they don't last as long as solution-dyed performance fabrics.

Step 3: Select High-Quality Notions

Long-lasting cushions require strong, weather-resistant sewing materials.

Best Thread for Outdoor Cushions

Use Tex 70 or Tex 90 (if you have an industrial machine) polyester outdoor thread, which includes UV protection and a non-wicking finish to prevent moisture absorption.

Best Zippers for Outdoor Cushions

Choose #5 molded tooth zipper components for durability. For cushions, you don't need a finished zipper. Order #5 molded tooth continuous chain and a compatible #5 single pull slider. We recommend Lenzip® or YKK® molded tooth zippers, known for their UV resistance, reliability and durability.

For more zipper options, check out our blog “Choosing the Right Zipper.”

Outdoor Cushion Fabric Foam Thread 6 — We've cut this cushion in half so you can see all the layers that we recommend for an outdoor woven fabric cushion.

Step 4: Maintain Your Outdoor Cushions

To extend the lifespan of your cushions and keep them looking like new year after year, here are some simple maintenance tips we recommend:

Vacuum regularly to remove dirt and debris.
Spot clean annually using a mild soap solution.
For tough stains, performance fabrics like Outdura, Sunbrella and SunRite can be cleaned with a bleach solution (check manufacturer guidelines for proper dilution ratios).
Apply 303® Fabric Guard™ (#481100) to restore water repellency and protect against stains (avoid spraying on zippers).

Winter Storage Tip: While outdoor cushions can withstand cold temperatures, storing them indoors during winter helps prevent unnecessary wear and potential critter infestations.

Final Thoughts

Now that you know the best foam, fabric and notions for outdoor cushions, you're ready to start your DIY project! For step-by-step sewing tutorials, search “cushion” on our website and explore the Outdoor Living DIY Projects page.

We hope this guide helps you create durable, weatherproof cushions that keep your outdoor space comfortable all year long. Have questions? Leave them in the comments below!