How Mattress Made

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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.

Where Was Your Mattress Made?

I did, so I started to do a basic search to find out what is readily available on the internet and what I already know. Here is the video were I walk you through the process of figuring out where some of these mattresses come from.

You can skip through the video to 1:07 if you are curious about Casper. Skip to 3:37 for the section on where the Nectar mattress is made. Purple is at the end at 4:37.

It gets kind of tricky, as some foreign companies will say that there team designed the mattress in the USA, but it was assembled elsewhere. So when in doubt we defer to the made in tag that they have to attach to the mattress, which is usually called the “law tag”. Fun fact about the law tag, even though it says do not remove under penalty of law, you can cut it off it it bugs you. That tag does not apply to consumers.

Since I filmed this Casper has released two new products: the Essential and the Wave. They released the information below showing where parts of their mattress came from. I consider Casper a global company, so I ask you the following. After reading the paragraph below, what country “makes” the Casper Wave?

Casper is a world wide company, which sources products from China, Canada, Mexico and multiple other countries to produce their products. When defending themselves from the Serta Simmons Bedding company they disclosed where each layer of the Wave comes from. “To construct the Wave, three different foam suppliers separately manufacture the five different foam layers in four different locations around the globe”. The top layer, which I LOVE, comes from Georgia. The second layer, the latex one, comes from Belgium. The third and fifth layers come from Montreal Canada. And the 4th layer, which is really the subject of the lawsuit is made in Indiana.

FXI robot which pours the polymer into the Casper Wave

So where was the Casper Wave “made”? You can answer below in the comments.

Updated 2019

I went back and watched this video today and realized that 2 of the companies that I listed are now out of business, Aloha Sleep and Matsleep. In addition, I noticed that some mattresses that had been made in China are now being produced domestically (likely due to Trump’s tariffs). For example, the Allswell mattress had been made in China and it is now being made in Brooklyn Bedding’s factory here in Phoenix, AZ. Trust me, I took the photos below on a tour.

Along the lines of the Allswell switch, Nectar has expanded into the UK market and those mattresses are produced in the UK rather than shipped from China.

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 Is Memory Foam Made?

Memory Foam Developed by NASA

The very first memory foam material was developed by NASA in the 1970s. Their intention was to try to improve seat cushioning and crash protection for airline pilots and passengers. Memory foam has widespread commercial applications, in addition to the popular mattresses and pillows you are familiar with today.

Anybody who has gone shopping for a bed, a new pillow, or even a new bicycle seat or mouse pad wrist rest in the last two decades will have encountered memory foam. This new material has been applied to a huge range of uses since its introduction to the US in 1991—from revolutionary medical uses to gimmicky new product designs. But what is it, who came up with it, and how does it work?

Though it is a relatively recent phenomenon in the US, memory foam has been around in various forms since the midpoint of the century—the first work on the polyurethane polymers that go into memory foam was actually begun in 1937 by Otto Bayer and his coworkers In 1965 the nursing staff at Lankenau Hospital tested “inert polyurethane porous foam” pads for use as bedding material, and found that they prevented “decubitus ulcers” (also known as pressure ulcers, sustained by patients who spend long amounts of time lying down), and found them to be hypoallergenic and resistant to bacteria (Kraus 1965). In the 1960s, NASA did work on materials that would serve as better cushions, and would also keep astronauts comfortable and protected from the extreme g-forces of lift off. It was then that memory foam as we know it came into being.

Memory Foam vs. Polyurethane Foam

Memory foam starts its life as polyurethane foam—a material first manufactured in the 1950s by adding water, halocarbons, or hydrocarbons to a polyurethane mix. Depending on the chemicals added and the way it is processed, polyurethane can form anything from car parts to spray liner, or in this case, one of the most comfortable sleeping surfaces the world has ever seen.

In the modern production of memory foam, a polyol is mixed with a diisocyanate and water. The foam rises like bread, with an open cell structure that helps give it its unique ability to spring back slowly from pressure. The introduction of gases into the initial solution creates a bubble matrix; vary the application of chemicals, and the size of the bubbles changes. A more open cell structure will have more give, and allow more airflow through the material.

Memory Foam Firmness

The firmness of memory foam is rated by the IFD (Indention Force Deflection), also known as ILD (Indentation Load Deflection) measuring the force in pounds required to make a 25% indentation in a 4 inch thick foam square. Also important in measuring the “softness” of a foam is the density. Foam densities range from 1-7 lbs, but a good-quality foam will usually be at least 4 and usually 5 lbs. A foam with a high density, but low ILD may still feel firm when compressed, especially in a lower room temperature. The density together with the IFD/ILD and the resilience will determine the softness, firmness, and life-span of the foam. Foam that is lower density will more readily conform to pressure, whereas higher density foam (usually 5-lb. or above) molds itself to contours when warmed by body heat.

Major production of memory foam did not begin until NASA released it into the public domain in the 1980s.Fagerdala World Foamstook up the challenge of producing this somewhat difficult product, and in 1991 produced the “Tempur-Pedic Swedish Mattress.” Today numerous companies around the world produce visco-elastic memory foam, which gives consumers increased variety and price range. Unfortunately, it also increases the risk of purchasing cheaply-made foams that may deteriorate over time. Not all memory foam is made equal, as many of the overseas manufacturers work at reducing the cost of memory foam by adding in other “filler” type ingredients that reduce the quality and potentially add toxicity to the formulation. The real problem with overseas foam is the lack of quality standards that have been created in the United States.

This American House

The life of the Delbert Meier House, an American System-Built Home designed by Frank Lloyd Wright.

12 Mattress Brands That Are Made in America

In our attempt to furnish the house with only secondhand or American made products, I found myself researching mattresses that are manufactured in the United States. As it turns out, there are quite a few mattresses companies with manufacturing facilities in the US. From traditional inner spring to the newer latex and memory foam mattresses, from budget to luxury brands, check out this list of American made beds.

  • Casper is the new kid on the mattress block. Covers and panels are sewn in Illinois and South Carolina and the foam for the mattresses is poured in Pennsylvania and Georgia.
  • Tuft and Needle mattresses are designed, sourced and manufactured in the States. The foam is poured and cut in the states, the fabric is sourced from a mill in the Carolinas and the mattresses are finished at a factory in California.
  • Kingsdown mattresses has been based in North Carolina for more than 100 years. They still produce some mattresses there, but they also have factories in California, Oklahoma, Virginia, as well as global manufacturing facilities.
  • The Original Mattress Factory has factory store locations in nine states, as well as available nationwide online. They offer both foam and pillow top mattresses.
  • Sealy mattresses are manufactured in three factories in the United States. The brand makes traditional innerspring mattresses, as well as hybrid, gel memory foam and latex foam mattresses.
  • Saatva Mattresses are produced in factories in twelve US states and are distributed through 35 fulfillment centers. The inner spring mattresses feature organic cotton covers and bio-based foam.
  • Englander has seven factories throughout the United States. They do not sell direct to the public so check mattress stores for the label.
  • Cozy Pure’s organic latex mattresses are manufactured in Norfolk, Virginia. The company also produces bedding and mattress pads.
  • Stearns and Foster mattresses are made in the USA, although I couldn’t find out exactly where.
  • Sealy operates 25 bedding plants in the U.S., producing both innerspring and foam mattresses.
  • EasyRest adjustable beds and mattresses are made in factories in Louisville and Georgetown, Kentucky and Nashville, Tennessee.
  • Thomasville Bedding Company has been manufacturing their mattress in Thomasville, Georgia since 1969. They make both innerspring and latex mattresses, as well as custom mattress and box springs.
  • Image: This American House

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    15 thoughts on “ 12 Mattress Brands That Are Made in America ”

    I love that everything you’re adding to your house is secondhand or American made! A themed home is a seriously unique concept.

    http://www.acmebeddingcompany.com/ Acme Bedding. Located in Muskegon, MI. Can customize to exactly what you want!

    A few other American made mattresses: Dutch Craft mattresses made in Celina, Tennessee. Jamison Bedding, made in Tennessee and a few locations in the western US. Verlo mattress company has several locations around the US.

    Oh and Corsicana Bedding from Corsicana, Texas. They also make these in Shelbyville, Tennessee.

    Add amerisleep and leesa

    Our furniture store sells American-made furniture – as well as Justice Mattresses made in Lebanon, Missouri.

    Have you seen http://www.loomandleaf.com or http://www.zenhaven.com ? They’re both American made luxury mattresses, one is memory foam and the other one is Latex.

    Have you seen https://drommabed.com? Dromma is a 100% Made in America mattress with triple layer, cooling gel memory foam. I sleep on one and love it.

    paramountsleep.com We have had their Nature’s Spa for almost 10 years! Still wonderful.

    Englander been into making Mattresses for over 125 yrs. Made in the USA!
    Many Englander manufactures are across the United States. Tualatin Sleep Products in the Northwest is in Tualatin Oregon and produces for 7 states OR,WA,CA,ID,NV,UT,AK
    Tualatin Sleep Products also manufactures other brands Eclipse,Eastman House.
    Family Owned & Operated-Better Sleep by Design
    (503)692-5510

    My wife and I really enjoy the Eco Terra – https://ecoterrabeds.com. It’s similar to the Zenhaven, but has actual third party certifications. It’s also a step above Casper.

    Casper memory foam mattresses are not made in the US but in China and shipped to warehouses through out the US.

    Amore’ mattress is made in Chicago, They also make a 12″ hybrid

    Such useful information! All these brands are quite famous and liked by the people of America.

    Trying to find out who makes the Calumet by Private Selection.

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