How to Replace Chair Cushion Foam

A chair with flat, uncomfortable cushions doesn't need to be replaced — it just needs new foam. Whether it's a dining chair, accent chair, or office chair, replacing the foam is a quick, affordable fix that restores comfort and extends the life of the piece. Here's how to do it.

What You'll Need

• Replacement foam: GoTo Foam 2" x 24" x 72" Firm Upholstery Cushion
• Batting wrap: PLANTIONAL Natural Cotton Batting
• Upholstery sewing kit: PLANTIONAL Upholstery Repair Sewing Kit, 47-Piece
• Staple gun: Metabo HPT Narrow Crown Stapler, 18 Gauge
• Screwdriver set: CRAFTSMAN Screwdriver Set, 8-Piece
• Putty knife: Rerdeim 5-Piece Putty Knife Set

Step 1: Identify Your Chair Type

Chair cushions come in two main configurations. Drop-in seat cushions (most dining chairs): the padded seat board unscrews from underneath — remove it and recover like a simple upholstery project. Loose cushions with covers (accent chairs, armchairs): the cushion has a zippered or sewn cover that can be removed to access the foam inside.

Step 2: Remove the Old Foam

For drop-in seats: Unscrew the seat from underneath, pry out old staples with a putty knife, and remove the old fabric and foam.
For loose cushions: Unzip the cover and pull out the old foam. If there's no zipper, carefully cut open a seam with scissors.

Step 3: Measure and Cut New Foam

Measure the old foam's length, width, and height. Cut new GoTo Foam to match, adding 1/2 inch to each dimension so the cushion fills the cover fully. Use an electric carving knife or sharp serrated knife for clean, straight cuts. For shaped cushions (curved front edge, tapered sides), use the old foam as a template.

Step 4: Choose the Right Density

For dining chairs and accent chairs used daily, choose a firm foam (43 ILD or higher) — it holds its shape longer and provides better posture support. For a reading chair or occasional-use piece, a medium foam (28–35 ILD) is more comfortable for extended sitting.

Step 5: Wrap with Batting

Wrap the cut foam with a layer of cotton batting and secure with spray adhesive. This softens the edges of the foam, gives the cushion a fuller appearance, and makes it easier to slide into the cover.

Step 6: Reinsert and Close

For loose cushions: Fold the foam in half to insert into the cover, then unfold and work into the corners. Zip closed, or use the upholstery sewing kit to hand-stitch any cut seams closed.
For drop-in seats: Attach the new foam to the seat board with spray adhesive, wrap with batting, then re-staple the fabric using the Metabo HPT stapler and screw the seat back onto the chair.

Pro Tips

• Order foam 1/2 inch larger than your measurements — a snug fit looks much better than a loose one.
• High-resilience (HR) foam lasts 2–3x longer than standard foam and is worth the investment for daily-use chairs.
• If the cushion cover is stained or worn, replace it at the same time as the foam for a complete refresh.
• Allow new foam to fully expand for 24 hours after unboxing before inserting into covers.
• For a chair with both seat and back cushions, replace both at the same time for consistent comfort and appearance.