Abstract: A chair includes a base, a back, and a seat with at least one of the back and seat including a cushion made from a non-woven fibrous material. A method includes steps of cutting a blank from a sheet of non-woven fibrous material, forming the blank into a preformed cushion shaped to support one of a user's back or buttock and thighs, and attaching the preformed cushion to a support panel to provide a stiffened cushion assembly and covering the cushion assembly to provide an aesthetically covered chair component.