The purpose of this study is to develop a lightweight and environmentally friendly nonwoven fabric to substitute polyurethane (PU) foams in automotive interiors. Two types of hollow fibers-polyethylene terephthalate (PET) hollow fiber and polylactic acid (PLA) hollow fiber-and bicomponent binder fibers were used to manufacture the nonwoven fabrics for seat cushions by carding, needle punching, thermal bonding, and air through bonding processes. The ideal characteristics required for automotive seat cushions were evaluated, and the significant changes with the structural components were analyzed. The nonwoven fabrics showed better air permeability, compressional resilience, ball rebound resilience, and non-flammability in comparison with PU foams. The characteristics were affected by the manufacturing processes.