As the warm weather continues to emerge, I’m looking forward to spending more time outdoors and enjoying our front porch. Last summer, we purchased inexpensive metal chairs, but since metal is not very comfortable to sit on, I finally got around to making a set of leave printed chair cushions. The best part is you can sew outdoor chair cushions in 30 minutes or less with a few specific materials and this envelope style pillow case.
How long it takes you will depend on your skill level, but as someone who is not an expert, I can assure you this should not take more than 30 minutes to make, so it’s a perfect “quick” project or a perfect project for beginners. This envelope style pillow case is very simple to make because it does not require zippers or stuffing, and you can easily remove the covers for washing anytime.
The key materials I suggest for this project are outdoor fabric (more durable, thick) and densified polyester pad in your desired size. I used a brand called NuFoam in size 15 x 17, 2 inches thick and simply trimmed it to my desired size because they did not sell the exact size. I found this to be the best material because it’s very light, washable and water will run right through it (as opposed to solid foam).
I ended up with size 15 x 16 cushions, so make sure you adjust your sizes accordingly. The materials below are per cushion.
- NuFoam densified polyester pad, size 15 x 17, 2 inches thick
- 1 yard outdoor fabric
- Scissors/rotary cutter
- Matching thread
- Sewing machine
First, cut the pad to the size of the chair. In my case, I cut about 1 inch off to create a 15 x 16 pad. Because the pads have layers, it’s easiest to cut only a little bit at a time.
Then cut one piece of fabric that is about 2 inches wider around than the pad (17 x 18 inches in this case), one piece that is 18 x 10 inches and one more that is 18 x 12 inches. These two pieces will create an envelope flap, so one should be slightly larger than the other.
On the larger flap (18 x 12), pin a thin seam along the 18-inch side and sew.
Pin all of the pieces together with patterned sides facing in and the sewn edge as the inner-most piece. This will be the one you see when the pillowcase is complete (see above).
Sew a thin seam all the way around the pillowcase without stopping, back stitching at each end. Trim loose threads.
Turn the pillowcase right side out and insert the foam piece. Place the cushion envelope-side down on a chair and lounge comfortably!
When it’s time to wash them, simply remove the foam piece and wash all pieces. They’re super easy to make and take care of, and they’re just as stylish as store-bought cushions!