New and improved foam cushions for packaging purposes of the type including a cushion envelope partially filled with an expandable cushioning foam material are provided. The cushion envelope includes a foam-receiving cavity and is defined by a unitary web of material folded over itself to provide a folded side. An intermittent labyrinth side seam is provided along the side opposite the folded side and transverse top and bottom seams are provided to complete formation of the cushion envelope. A cushioning foam is disposed in the foam-receiving cavity. A method for making the foam cushions and an automated apparatus for making a continuous supply of the packaging cushions are also described.