How to Make a Bean Bag

The Giant DIY Challenge

So, you're thinking of making your own giant bean bag? Maybe you love a hands-on project, or you think it might save you a buck. We hear from so many customers who’ve tried this as a project and get a lot of questions about the process, so let’s dive into the details! In this guide, we’ll walk you through the full process of making a DIY bean bag, from start to finish. But fair warning: it’s not as easy (or as cheap) as you might think.

Step 1: Designing the Pattern for Your Bean Bag Lining

The inner lining is what holds the filling inside your giant bean bag. You’ll need to create a custom pattern—this is typically a spherical or teardrop shape, depending on your preferred style. There are tons of patterns available for download online, so google is your friend her.

Materials: Durable calico or strong polyester lining fabric.
Tools: Tape measure, chalk, scissors, pins, and a sewing machine.
Process: Draw and cut six to eight identical panels that will form the 3D shape. You’ll need to sew them together, leaving a sizeable opening to insert a zip later.

If you're not confident with sewing patterns, be prepared for trial and error. You'll likely need to redo a few panels until they line up properly.

Step 2: Sewing and Adding the Zip to the Lining

Once your panels are stitched, you need to install a strong zip (at least 60cm) into the seam. This zip is essential—not just for filling the bean bag, but for any future topping-up or maintenance.

Getting the zip aligned and securely attached can be tricky. If it’s not stitched properly, it may burst open under pressure, especially in a giant bean bag where the weight and volume of foam are significant.

Step 3: Creating the Outer Cover

Now it’s time to create a stylish, removable outer cover. This is the part people will see and feel, so choose your fabric wisely—think velvet, faux fur, canvas, or cotton twill.

Use the same panel pattern as the inner lining
Reinforce seams with double-stitching to ensure long-term durability.
Add a second zip for easy removal and cleaning. We use YKK zips at Happy Sak as they’re the most durable and highest quality.

Want contrast piping or a pocket? Add that now!

Step 4: How to Fill Your Giant Bean Bag

You’re almost there—but now comes the most labor-intensive part: filling your giant bean bag.

Where to Get Foam

Forget those tiny polystyrene beads—they’re messy, environmentally unfriendly, and offer poor support. The better choice? Chipped foam. You’ll need to find a local foam or mattress factory or upholstery supplier willing to sell you a few kilos of foam offcuts. You may run into issues here as these aren’t usually sold in small batches, and delivery can be expensive, so be prepared for that.

Filling the Liner

Stuffing chipped foam into your giant bean bag lining is a two-person job. You’ll need to:

Break down large chunks of foam into smaller bits by hand (unless you have a chipping machine of course!);
Funnel them into the lining carefully—we use a large plastic tube attached to bags of foam for this job at Happy Sak;
Zip it up fast before foam starts flying everywhere – those tiny little pieces get into every nook and cranny imaginable!

Most people underestimate how much foam is needed. A large adult-size giant bean bag may require 8–12 kg of foam, costing upwards of R850–R2500, not including fabric or zips.

Summary of Costs

Let’s recap:

Lining Fabric: R500–R1000 depending on size
Cover Fabric: R1200 – R4000 depending on size and material
Zips: R100–R200
Foam: R850 – R2500
Time: 8–10 hours across multiple days
Tools Needed: Sewing machine, overlocker, measuring tools, scissors, workspace

Or… Just Buy a Bean Bag from Happy Sak!

At Happy Sak, we’ve already done the hard part for you. Our giant bean bags are made using premium fabric, double-stitched seams, heavy-duty zips, and luxuriously soft foam fillings—no guesswork, no mess, no stress.

With dozens of colour and fabric options, fast delivery, and a proven design perfected over years, your dream giant foam bean bag is just a click away.

Why DIY when you can Happy Sak?