How Mattress Are Made

Home   /   How Mattress Are Made

How Mattresses Are Made

This content was created by the National Sleep Foundation

Mattress construction from the inside-out

If reading about mattress construction sounds like a real, ahem, snooze, know this: The way a mattress is made determines how it feels. And how a mattress feels may be the difference between a fitful night and peaceful slumber!

The Big Picture

Two basic types of mattress make up the vast majority of the market: They’re called innerspring and memory foam. Made of steel coils, innerspring is, by far, the most common type. Memory foam, on the other hand, is made from polyurethane or latex foam, and is very dense foam. Memory foam is usually more expensive than innerspring.

Inside an Innerspring Mattress

Coils determine how much support (suspension versus springiness) the mattress will give. Manufacturers may use different types of coil shapes and structures, as well as different amounts of spacing and patterns to affect comfort. The next layer, top padding, isusually made from polyurethane foam. The outer layer (or ticking) is the material bound to the top padding with stitching. The way that ticking and top padding are attached influences the mattress’s overall feel. Large, wide patterns will create a cushioned feel, which smaller patterns feel tighter and firmer. Generally, the more coils an innerspring mattress contains, the more comfortable it’s bound to be—but if the number of coils is over 390, then you’re not likely to notice the difference, so don’t bother paying extra.

Inside a Memory Foam Mattress

Especially attractive to people with chronic pain conditions, memory foam mattresses consist of, essentially, very dense foam. When you lie on a foam mattress, your body heat softens the material, allowing it to “mold” to your body. One big advantage: In bigger beds, a memory foam mattress won’t shift as much as an innerspring when one partner turns or moves. So if you’re often disturbed by your partner’s tossing and turning in the middle of the night, it might be time to invest in a memory foam mattress. But one con: Because these mattresses mold to your body, they can absorb a lot of heat and make you feel hotter while you sleep. Some people also complain that they have a chemical smell.

How Latex and Memory Foam Mattresses Are Made

There are a couple of reasons why you might be interested to read what I have on this section of my website. The first is that you have a natural curiosity about how the products you buy are made, and considering you’ll be spending up to one third of your life on a mattress, I can’t blame you for wanting to know.

The second reason might be because you’re concerned over how eco-friendly a mattress is, and again, I can’t blame you. After all, we’re constantly told how we should treat our planet better and the dangers that certain materials can pose to our health.

So, no matter what the reason I thought it would be a good idea to let you know how latex and foam mattresses are made. Of course, if you’re familiar with latex you may think this is the most natural substance a mattress can be made from, and you would be right since the raw material is drawn directly from the rubber tree.

However, if you are erring on the side of a latex mattress do be careful of the actual amount it contains because manufacturers use three different forms: 100% natural, 85% natural and 15% synthetic and finally 20% natural and 80% synthetic. Of course, the more natural a latex mattress is the more expensive it will be.

In respect of memory foam mattresses, the materials used are synthetic and this is one of the reasons why I come across so many complaints about the “outgas” odor many of them give off when they’re brand new. Whilst this can be a little worrying, if you’re careful to look for the CertiPUR-US certificate this will guarantee that your mattress is gentle on the environment and isn’t bad for your health.

If you’re interested in finding out about the whole process, why not have a little peek at the short video I have included below?

How Are Air Mattresses Made?

Air mattresses offer an affordable bedding solution for millions of people all over the world. From camping to other outdoor activities, lots of people are able to enjoy nature thanks to these mattresses.

They are equally great for sleeping indoors whether you have kids coming over or family on their way. even if you have the worst inflatable mattress in the world.

This is why these types of mattresses inevitably pop up in the minds of consumers as soon as they think of temporary bedding.

So, how are inflatable mattresses made? What kind of materials go into the manufacture of these units?

If you have been getting quality use out of your mattress then you’d probably want to know how they are manufactured.

Even if you have never owned one of these mattresses, it still pays to know.

Stick around as we go through some of the materials that go into the manufacture of these portable mattresses.

Who knows? This may help point you in the right direction the next time you decide to shop for an air mattress.

Polyvinyl chloride (PVC) is one of the most popular materials in the airbed industry. If you have been doing a little bit of research on these units then you may have come across some popular models manufactured from this material.

While lots of affordable mattresses are manufactured with PVC, it is not uncommon to find some high-end models made from it too.

Advantages of PVC Air Beds​

There are lots of advantages you stand to gain from mattresses manufactured by PVC. Here are a few of them.

Waterproof

One of the main reasons for the popularity of PVC the waterproof capabilities. Mattresses made with this material give you a waterproof surface to enjoy your sleep.

The fact that inflatable mattresses are waterproof unlike regular ones makes it suitable for the needs of many consumers. While regular beds can get wet when water or another liquid spills on it, inflatable ones have been traditionally different.

Waterproofing comes in handy in blowup medical mattresses and those relied upon by the bed-ridden.

Low Maintenance

When shopping for an airbed, it is important to choose one that is low maintenance. We live in an era where everyone is extremely busy so you wouldn’t want to waste time keeping your mattress in good shape.

This is what gives PVC an edge over the other materials used in the airbed manufacturing industry. It requires no need for washing, drying, and any of those tedious activities.

However, if you insist oncleaning your mattressperiodically then you can simply get it done with a piece of washcloth and water.

This is another advantage these mattresses have over regular ones.

​Fire Resistant

While most regular mattresses are unable to withstand fires, this is a problem PVC airbeds do not have. Manufacturers apply specific chemicals on the surface of these airbeds to ensure their ability to stay in their original physical condition even when exposed to fire.

This feature is especially handy because non-PVC air mattresses are mostly manufactured from plastic or other materials which crumble when exposed to fire.

Cheap Manufacturing Process

One of the reasons why air mattresses have become so popular is the fact that they are significantly inexpensive. Industry experts have revealed that manufacturing them with PVC comes at significantly lower costs when compared to the others.

Industry players are therefore able to make their product lines available to consumers at affordable prices. You definitely do not have to break the bank in order to get a quality inflatable mattress.

Disadvantages

As expected, there are some drawbacks that come with inflatable mattresses manufactured from PVC. Here are a few of those:

Toxic Material

PVC is far from the cleanest material in the inflatable mattress manufacturing industry. In fact, this plastic has been found to be toxic and harmful to the environment in so many ways.

Vinyl chloride, a sub-component of the material results from the combination of plastic and petroleum.

Production causes the release of toxic chemicals into the environment. If you are green-conscious then you may have to look for one manufactured from alternative materials.

Less Comfortable

It is no secret that PVC is a plastic material. It is quite hard in its basic form meaning it doesn’t make the most suitable sleeping surface. Some additional chemicals are added during the manufacturing process to soften and make it more comfortable.

Phtalates are the most popular chemical added to PVC to make it soft during the manufacturing process.

This chemical can be absorbed into the skin while you are sleeping. It has been linked with severe medical conditions such including cancer and asthma.

Other Manufacturing Materials Used in Air Mattresses

Textile-reinforced urethane and rubber are alternate materials used in the manufacturing of airbeds. They are quite popular and usually found in some of the high-end models available for sale.

Advantages

Here are a few advantages of going in for an airbed manufactured from rubber and textile-reinforced urethane.

Thicker and Puncture-Resistant

The advantage of textile reinforced urethane is they are more puncture-resistant and thicker than PVC. This means that buying a mattress made from one of these gives you more comfort and durability.

The advantage of textile reinforced urethane is they are more puncture-resistant and thicker than PVC. This means that buying a mattress made from one of these gives you more comfort and durability.

True, there may be lots of ways to fix punctures in your mattress. However, how would you feel about having a mattress with minimal risk of puncturing in the first place?

Absence of Phtalates

Thermoplastic urethane airbeds contain no phthalates. You can therefore sleep on them without risk of developing any medical issues. These mattresses typically come with no odors, which is another problem arising out of phthalates.

Disadvantages

The main disadvantage of choosing an airbed manufactured from thermoplastic urethane is the expense. The high cost of manufacture means they are relatively more expensive than models from PVC.

The Verdict

We hope you have learned a few things about the manufacturing process of air mattresses and are in a better position to make a sound choice.

If you want something environmentally friendly and willing to pay the full cost then thermo urethane is a good choice. Rubber is another great choice if your budget is not too tight.

On the other hand, PVC mattresses hit you less in the wallet and are great for consumers with low budgets.

How is a Latex Mattress Made?

February 28, 2018

There has been a growing focus on healthy living over the past few years. Consumers have made it known, that they want to sleep on mattresses that are made using natural materials, to support their new, healthy lifestyle.

Why a Latex Mattress?

It’s simple. An Eco Terra mattress is made using natural and safe materials. Therefore, they offer safe sleeping surfaces. It’s true that we spend approximately one-third of our lives sleeping in our beds. Everyone deserves to spend this one-third of their lives sleeping on a mattress that doesn’t contain toxins. Our latex mattress is toxin free and the healthiest mattress you can sleep on. Also, our latex mattresses are made with natural and quality materials, so they last longer than other mattresses made today.

Eco Terra Latex Mattress

The Eco Terra mattress is a popular mattress that comes with an impressive 15-year warranty. Impressive because most mattresses are expected to only last an average of seven years, with a warranty to match.

The Eco Terra mattress also offers sleepers:

  • Superior posture support due to eliminated negative space (which is recommended when it comes to properly aligning the spine).
  • A cooler sleeping service due to its breathability (which means it disperses the body’s heat when sleeping).
  • The ability to not disturb their partner when moving while sleeping due to advances in minimized motion transfer.
  • Edge to edge comfort from the quantum coil reinforcement design, which means you’ll sleep just as comfortably when in the middle of the bed as you will when you’re on the edge of the bed.

Where do Latex Mattresses Come From?

Rubber trees. The material used to make a latex foam mattress is harvested from rubber trees, which for the most part grow on sustainable plantations. Eco Terra gets their latex from rubber trees grown in Sri Lanka, as the majority of rubber tree plantations are located in the Southeast Asia area. The environment in Southeast Asia fully supports rubber tree growth, and many people agree that the more trees planted, the better. Trees are extremely beneficial to the environment, and as more and more people buy latex foam natural mattresses there will only continue to be more trees planted.

How are Latex Beds Made?

Our Eco Terra mattresses are made using environmentally-friendly mattress-making methods, which is another reason why latex mattresses are so popular nowadays. A special method is used to extract the white liquid sap from the tree, while at the same time providing no damage to the tree in any way. In order to extract the white sap, a small cut is made on the tree to remove the bark that will cause the sap to begin to flow out of the tree; it can take up to 6 hours for the sap to stop flowing. Buckets are placed under the flowing sap for transport.

The fact that rubber trees can be used for more than 25 years for this purpose is quite remarkable!

Talalay vs. Dunlop

So how does the liquid sap that coming out of a rubber tree create a healthy mattress? There are two main methods used to produce a latex natural mattress – the Dunlop Method and the Talalay Method. Each method has its own way of processing and one is not necessarily better than the other one. It’s simply a matter of mattress preference.

  • The Dunlop Methodis the original all-natural mattress making method that has been used since 1929, and it tends to create a firmer texture, which is typically used as a mattress core in 100% natural latex mattresses. This method requires the sap to be mixed until it turns into a foam, which is then shaped by putting it into a specially made mold, then into a hot oven to create the all-natural latex mattress. The mattress is then thoroughly cleaned and dried. This particular mattress-making method allows the entire mattress to be made at one time.
  • The Talalay Methoduses a process that produces a latex bed with a little bit of a different texture, which tends to make it softer than the Dunlop Method. It is typically used as the top comfort layer in mattresses. Instead of mixing the sap into a foam, it is put into a specially made mold which is closed tight. Suction is then used to make sure the sap is evenly distributed. The next step requires the mold to be frozen and then quickly heated, which causes the sap to become solid.

Because the Eco Terra mattress has a supportive base of fabric-encased coils, the top layer is made of the softer, airier Talalay latex for supreme cushioned comfort.

Eco Terra Mattress = The Preferred Mattress Choice

So now you know why a mattress made with natural latex is quickly becoming the preferred mattress choice among mattress buyers. The healthy living movement is here to stay and more and more people are looking to buy a safe mattress to sleep on. This allows them to create the safe sleeping environment which they not only deserve, but need, for their overall good health.

High-quality, latex foam mattresses receive the highest overall owner satisfaction ratings.

The ULTIMATE guide to know how foam mattresses are made

You wake up one morning with a terrible backache. Your bed is now as comfortable as a cot, except that you are at home. So you plan to change it, and consider getting a foam mattress, a type of mattress that your colleague Cathy keeps raving about at the office, so much so that she radiates rest every morning. You want to learn more about it, and you google: what materials are used? How are these mattresses made? These are the questions you ask the all-knowing search engine. And boom, you happen uponour guide on how foam mattresses are made!

« Ok Google, what kind of foam is used in foam mattresses? »

And re-boom! Google says: “There is not just one type of foam, there are many different types used for foam mattresses.” And as always, Google is right. Here are the different types of foam used in foam mattresses and their properties!

Memory Foam

The first, and certainly the most promoted at the moment, is memory foam. This type has the particularity of reacting to temperature and pressure to perfectly fit the morphology of the person during their sleep. The only problem: if the room temperature is low, the foam will be hard as stone while it warms up in contact with your body. In addition, it tends to store your body’s heat; you’ll feel way too warm in the summer if it’s not infused with thermoregulating gel!

Latex foam and high-resilience foam

An alternative that overcomes the disadvantages of memory foam is foam made of latex. It offers all the advantages of memory foam, but with the particularity of being hypo-allergenic, in addition to its thermo-regulating properties. The result: no allergies, and you always sleep at the right temperature! Another type of highly breathable foam is high-resilience foam, which offers a high level of breathability thanks to its cell structure, which also allows for excellent moisture absorption.

Polyurethane foam and polyether foam

Next come polyurethane foams. These, as already mentioned in ourUltimate Guide to Foam Mattresses, are the ones with the best price-performance ratio due to their high durability, linked to the fact that the density of this type of foam is high to very high. They also ensure a first-rate long-term support with the particularity of strongly reducing the transfers of movement. Let us also mention a more economical alternative but with a shorter lifespan: polyether foam, with lower density.

« Ok Google, what are the steps involved in making a foam mattress? »

To which Google replies: “Hang on to your hat!” And once you learn the different steps to build a foam mattress, you’ll understand why!

Choosing the materials for the mattress.

This is logically the first step. Trying to choose the materials after you’ve built the mattress doesn’t work! And first of all you have to choose the ticking, which is the fabric covering the whole mattress. Depending on the manufacturer, it can be made of different materials such as linen, cotton or bamboo viscose. Others will turn to synthetics, for example with polyester ticking. There will also be the choice of the different types of foam that make up the layers of the mattress, which will depend on the range level of the mattress (and therefore the price), and the properties required for each of them.

Cutting the fabric to the right dimensions.

This is a crucial step. This consists of cutting two pieces of fabric, called “panels”. During this operation, the most important thing is to make sure that each of them is exactly the right size for the size of your mattress, otherwise it’s going to get complicated!

Processing and cutting the foam and then cutting out the quilting elements

Whatever the type of foam to make, the process is the same: it’s like making a cake! In other words, atPolysleep, the people in charge of designing our foams could have been pastry chefs.

Joking aside, the foam is first poured into a large tray, then placed in a gigantic oven to bake it, which will gain in volume before cooling down. Once baked, the foam is cut into sections the size of the mattress. The properties of the foam will vary according to the ingredients added to the foam “recipe”, which will give it a higher or lower density. Next comes the cutting of the various parts that make up the padding, such as wadding or contact foam.

But at Polysleep, for thePolysleepandZephyr models, we add an extra twist to further increase the mattress’s longevity, with ultra-firm contours that prevent any premature sagging of the layers! This is accomplished with a contour near the edges of all foam layers to reinforce the mattress structure.

Assembling the different parts of the mattress.

The first step will be to assemble the different layers of foam. And for this purpose, glue will be used to make the different foam sheets stick together. Once this step has been completed, if the model has been designed with handles and holes for ventilation, a surrounding strip will be sewn, which can be placed on the mattress later.

Pre-closing the mattress.

It is at this stage that the second piece of fabric is placed on the mattress. This is joined to the first with large pins to connect them together.

Mattress tufting.

Then it’s time for tufting the mattress. The number of tufts will vary according to the size of the mattress: for reference, a 140 cm x 200 cm mattress will require 32 tufts. Usually, these are made with a 45 cm needle, which must pass through the mattress from one end to the other to compartmentalize the foam in specific areas. This step is important because the resulting partitioning of the materials allows them to be held in place over time, thus providing long-lasting support and comfort. The two panels of fabric are then permanently joined by sewing them together to close the mattress once and for all!

Modeling the mattress.

When there’s more, there’s more! Don’t worry, this is the last step. It consists of shaping the mattress, by making beads on the “edges” of the mattress. These, called “tamping lines”, are used to obtain the final shape of the mattress, and are made with a large needle (15 cm!). But far from crossing the mattress from one edge to the other, the needle will only get a little foam on the contour to make a frame for the mattress along its entire length.

Add a Comment: