Cushion Talk

At Willow Creek Teak we manufacture our outdoor cushions to the highest standard of materials, construction and comfort. We are a full cut and sew factory and manufacture exclusively with Sunbrella fabric. Our cushion is cut with a automatic cnc fabric cutter. We invested over 100k into the machine to produce parts at an exacting tolerance. Each part is over locked to create a clean strong stitch. Each seat cushion is made with closed cell foam and wrapped with a pillow top dycron on 3 sides for ultimate comfort. We use a loose fill back cushion in a sewn ticking bag for containment. The filling allows for the client to be sucked into the material for lounging comfort. Machine stuffed and bagged for protection in transit. We manufacture over 6500 cushions per year.

Follow along as we make some cushions:)

Sunbrella fabric bolts
Cnc Eastman automatic fabric cutter
Sunbrella Black on the table. Ready to be cut
Cnc program with club chair cushion parts
Overlocking parts edge before assembly
Sewing parts together including zipper and pull
Sewn seam
Deep seating 5" seat foam
Deep seating loose fill back cushion
Deep seating combo seat and back cushion 
Time to stuff the seat. 
Foam compressed to insert into seat fabric
Foam inserted. Just Zip
Back cushion inserted. Just zip
All zipped up. Combo is complete
Just like a cushion spa. 
Bagged for protection in transit
Sewing workspace

Thank you for following along. We look forward to making a set for you.