Cushion and Cover Fabrication

We design and fabricate certified seat cushions, dress covers, and soft goods for commercial, executive, and VIP aircraft interiors.

Custom Cushion and Cover Fabrication for Aircraft Seating

AIRO Industries Company operates a full service cushion and cover fabrication shop dedicated to aircraft seating. We design, cut, sew, and assemble seat cushions, dress covers, headrest covers, armrest covers, and related soft goods for Tourist Class, Business Class, VIP, cockpit, and cabin crew seating across commercial and executive aircraft.

Every product that leaves our shop is built to meet flammability, durability, and fit requirements specified by the seat manufacturer and the aircraft operator. We work with a full range of aviation grade materials including leather, Ultraleather, wool blends, and fire blocked foam to deliver cushions and covers that perform in service and meet all regulatory standards.

Custom foam cushion fabrication to OEM specifications

Dress cover design, patterning, and sewing

Full material sourcing for leather, textile, and foam

All products certified to FAA flammability and performance standards

We produce bottom cushions, back cushions, headrest pads, armrest pads, and leg rest cushions for all seat classes. Every foam product is tested and certified to meet the applicable FAR 25.853 flammability requirements before installation.

Seat cushions are one of the most frequently replaced components in aircraft interiors. Foam breaks down over time from passenger use, UV exposure, and the pressurization cycle, leading to reduced comfort, uneven support, and failed flammability compliance. AIRO Industries Company fabricates replacement cushions using aviation grade fire blocked foam, cut and profiled to match OEM dimensions or custom operator specifications.

Foam Cushion services include:

Bottom seat cushion fabrication

Back cushion and lumbar support pad fabrication

Headrest and armrest pad replacement

Custom foam profiling for VIP and executive seating

Fire blocked foam selection and certification

FAR 25.853 flammability compliance on all foam products

DRESS COVERS AND UPHOLSTERY

Dress covers define the look and feel of every seat in the cabin. AIRO Industries Company designs, patterns, and sews dress covers for all seat classes using aviation approved materials. Whether the requirement is a fleet wide economy cover replacement or a custom leather finish for a VIP suite, our sewing shop delivers precision fit and consistent quality across every unit.

Business Class services include:

Seat cover patterning, cutting, and sewing

Headrest, armrest, and leg rest cover fabrication

Seat shroud and back panel cover production

Color matching and stitch pattern replication

Fleet volume production with consistent quality

Custom one off covers for VIP and executive programs

MATERIALS

Every material used in our cushion and cover fabrication meets the flammability, durability, and performance standards required for aircraft interiors. AIRO Industries Company sources materials directly from approved suppliers and maintains relationships with leading manufacturers to ensure availability, consistency, and competitive pricing.

Materials include:

Leather and Synthetic Leather

Textiles and Fabrics

Foam and Padding

WHY OPERATORS CHOOSE AIRO FOR CUSHION AND COVER FABRICATION

aircraft cabin. They define the passenger experience and reflect directly on the operator’s brand. AIRO Industries Company combines in house fabrication capability with strict material standards and FAA compliance to deliver products that look right, fit right, and hold up in service.

Fabrication shop with full cutting, sewing, and assembly capability

Volume production for fleet programs and custom work for VIP cabins

Direct material sourcing from approved aviation suppliers

All products certified to FAA flammability and performance standards

AIRO Industries Integrated Aircraft Interior Capabilities

Frequently Asked Questions

Some frequently asked questions about the service that you may have questions about

What types of seat cushions do you fabricate?

We fabricate bottom cushions, back cushions, headrest pads, armrest pads, and leg rest cushions for all seat classes including Tourist Class, Business Class, VIP, cockpit, and cabin crew seating.

Which materials do you work with?

We work with aviation grade leather, Ultraleather, wool and wool blend fabrics, fire retardant synthetic textiles, and fire blocked polyurethane foam. All materials meet the required flammability and performance standards for aircraft interiors.

Can you match existing seat colors and stitch patterns?

Yes. We provide color matching and stitch pattern replication services to ensure new covers are consistent with the existing cabin appearance. This applies to both individual seat replacements and full fleet programs.

Do you handle both fleet volume orders and custom VIP work?

Yes. Our fabrication shop supports high volume production runs for commercial fleet programs as well as custom one off projects for VIP and executive aircraft, with the same quality standards applied to both.

Are your cushions and covers compliant with FAA flammability requirements?

Yes. All foam cushions and dress covers are fabricated using materials that meet FAR 25.853 flammability requirements. Testing documentation is provided with every order.

Can cushion and cover work be part of a seat overhaul program?

Yes. Cushion and cover fabrication is frequently performed as part of complete seat overhaul and cabin refurbishment programs, with our fabrication, seat, and interior teams coordinating the full scope of work.