How Mattresses Are Made Video

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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.

Making the Perfect Mattress

Hand Crafted Comfort

The Puffy Mattress is the culmination of four years of research and development, foam formulations, and sleep trials. We believe, as do the majority of our customers, that we have crafted the perfect sleep system — especially for those with back pain.

It’s no secret that foam, especially higher quality foams such as those used in the Puffy, can only be compressed tightly for so long before degrading in quality. To ensure you receive your mattress in immaculate condition, we make, compress, and package our mattresses in smaller batches so they are only compressed for a week or two before you receive it.

Made the Right Way

100% Manufactured
in the USA

OEKO-TEX®️
STANDARD 100 CERTIFIED.

Choosing the best mattress type

Find the best mattress for your body and budget. We look at the pros and cons of different types – from memory foam mattresses to pocket sprung and latex.

Put us to the test

Our Test Labs compare features and prices on a range of products. Try Which? to unlock our reviews. You’ll instantly be able to compare our test scores, so you can make sure you don’t get stuck with a Don’t Buy.

Memory foam, pocket sprung, latex, open coil, continuous coil. not sure which type of mattress is best for you? We look at the pros and cons of the main types of mattresses to help you find the best.

There are four main mattress types to choose from. Most mattress manufacturers make more than one type – different varieties go through a different manufacturing process and cost different amounts. Price isn’t everything, though, as what is most important is what you as an individual find comfortable.

Read on to help you decide which type of mattress to buy. Once you’ve made up your mind, you can use the filters on our independent mattress reviews to find your perfect mattress.

Spring vs foam mattresses

Watch our video below to find out the key differences between the main mattress types, including what each one is made up of and how it will affect your sleep.

Use our interactive tool below for more information on the differences between spring and foam mattresses.

Keep reading for more information on the main type of mattress. Or, if you already know which type you want, find out how to buy the best mattress.

Pocket sprung mattresses

In pocket sprung mattresses, the springs are sewn into individual fabric pockets. Pocket sprung mattresses are the most popular type of mattress among Which? members – more than half of the members we surveyed about their mattress had bought a pocket sprung one.

Pocket sprung mattresses don’t mould to your shape in the same way that memory foam mattresses do, but that doesn’t necessarily mean they offer less support. They also tend not to be as warm as memory foam mattresses, which could be an important consideration if you tend to find yourself too warm at night.

We’ve tested some great pocket sprung mattresses at a range of different prices, so you’re sure to find one that suits you. Go to our Best Buy mattresses page to see the very best.

Memory foam mattresses

Memory foam mattresses, also known as memory mattresses, are topped with a layer of temperature-sensitive viscoelastic material (memory foam). They can be expensive, but we’ve found some fantastic memory foam mattresses for less than £400.

This makes the shape of the mattress change to fit the shape of your body, and it also tends to make the mattress feel warmer.

Everything you need to know about this increasingly popular type of mattress can be found in our memory foam mattresses guide.

If you already know that you want to buy a memory foam mattress, you can find the right model for your budget and body type by reading our mattress reviews.

Continuous coil and open coil spring mattresses

These mattresses are cheaper than other types of bed mattress.

  • Continuous coil mattresses are made from a single looped wire
  • Open coil mattresses are made of single springs fixed together by one wire.

Because the springs move as one unit, you’re more likely to be disturbed by your partner moving around during the night. The coils in these mattresses wear out more quickly than pocket springs, so you’re likely to end up rolling together eventually.

When we surveyed Which? members to find out more about mattresses, those who own an open-coil mattress are less likely to say that it helps them to get a good night’s sleep than those who own other types of mattress.

You can find out more about our survey results, including which brands to look out for, in our full mattress brand reviews.

Latex mattresses

Latex is a less common type of mattress which features a core made up of layers of springy latex. These mattresses tend to be more expensive, but manufacturers claim that they are more resilient and able to better keep their shape.

Manufacturer Dunlopillo specialises in latex beds, although the Dunlopillo mattresses we’ve reviewed don’t come cheap.

Mattress toppers

These are different from mattress protectors in that they add a layer of extra padding to your existing bed. Mattress toppers can be made of memory foam or other materials. However, they can be as expensive as buying a new mattress in some cases, and won’t provide more support if your old mattress is already sagging.

Discover which are the best mattress topper brands according to our survey of more than 1,000 mattress topper owners.

How to Pick Your Perfect Mattress

Ready for a new mattress? Here’s how to find the one that suits you best.

Getting a good night’s sleep depends on a lot of different factors — comfort, stress level, room temperature – but to get it right, you’ve got to start with the basics and your mattress is the first building block to a restful slumber.

If you’re in the market for a new mattress and have recently taken a stroll down the aisle of a bedding store, you know that there is a dizzying array from which to choose. How do you know which mattress is best for you?

To start, says Arya Nick Shamie, MD, associate professor of orthopedic surgery and neurosurgery at Santa Monica UCLA Medical Center, the mattress needs to support your body in a neutral position, one in which your spine has a nice curvature and your buttocks, heels, shoulders, and head are supported in proper alignment

"If the mattress is too firm, it will push on those main pressure points and take you out of alignment," Shamie tells WebMD. "If it’s too soft, those pressure points won’t be properly supported, so your whole body flops back." Both of these scenarios can lead to an achy morning.

Generally speaking, one type or brand of bed isn’t better than another, says Michael Breus, PhD, a WebMD sleep expert and author ofBeauty Sleep: Look Younger, Lose Weight, and Feel Great Through Better Sleep.But he does find that a firmer bed seems to be better for people with lower back pain.

In fact, researchers in Spain studied people with long-term back pain and found that on a 10-point hard-to-soft scale people who slept on a medium-to-firm mattress (5.6 on the scale) had less back pain than those who slept on a softer mattress.

Is It Time for a New Mattress?

How do you know if the bed you’re sleeping on is the right one?

"If you wake up in the morning and have some low back pain and can stretch and get rid of it in 15 or 30 minutes, that means you’re on an inappropriate mattress for you," Breus says.

The right mattress, on the other hand, is one on which you feel no pressure, almost like you’re floating in air, Breus says.

If you’re looking for a new mattress, experts suggest testing it in the store and laying down on each mattress in the position in which you normally sleep. Breus suggests spending at least 10 to 15 minutes on the bed. And, bring your own pillow! The more you can replicate the way you’ll be sleeping on the mattress once you get it home, the better your chances of picking the right one.

Continued

Innerspring Mattresses

Innerspring mattresses are still by far the most widely used. They support you with coil springs, and in most built today, each coil is individually enclosed. This helps the bed weather years of use and prevents the coils from popping out of the mattress. On top of the coils are a wide variety of materials added for comfort, from pillow to latex to memory foam. It’s all a matter of preference.

Salespeople may try to sell you on the idea that more coils mean more comfort, but that’s not necessarily true, Breus and Shamie say.

"You don’t really need a coil count above 390," Breus says. Beyond that, the difference in feel is so small it would be difficult to notice.

Pros:There are plenty of innerspring mattresses on the market from which to choose. They range in firmness, the fluffiness of the pillow top, and in price to fit nearly every preference and pocket book.

Cons:There’s no direct relationship in most cases between price and comfort, but Shamie suggests steering clear of the cheapest innerspring mattress. If there aren’t enough springs and cushion to offer you proper support, he says, you’ll likely wake up with an aching back.

Conditions:For someone who is very overweight, spring mattresses may offer a firmer support, making them easier to get in and out of, Breus says. Firmer versions are good for people with back pain. But spring-based mattresses can be comfortable for almost anyone.

Memory Foam Mattresses

Memory foam mattresses are growing in popularity. They are made of layers of different densities of foam that respond to weight and temperature, and are known for comfort because they contour to the specific shape of your body. Memory foam toppers are also available.

Pros:By molding to the shape of your body as your weight shifts through the night, memory foam reduces pressure points, and relieves pain. Memory foam also absorbs movement, so if you sleep with a partner, you’re not likely to be disturbed by his tossing and turning.

Cons:One of the biggest complaints with memory foam mattresses is that because these mattresses are temperature sensitive, softening and molding with your body heat, they can make you feel extremely hot during the night. Breus also says memory foam mattresses have been known to emit an unpleasant chemical smell.

Conditions:"If you have a hard time getting comfortable, if you have chronic fatigue, or some type of muscle pain, then a memory foam mattress would work well for you, assuming you don’t have temperature issues," Breus says.

Continued

Latex Mattresses

Latex mattresses are made from either natural or synthetic rubber, and are known for providing a very firm, bouncy support that is uniform throughout the bed.

Pros:"Quite frankly, I think one of the best materials is latex," Breus says. He likes it for being very firm and supportive, but also for providing comfort similar to memory foam. Unlike the memory foam mattresses, however, Breus says latex pushes back, ultimately providing more support.

Cons:If you don’t like the feel of a firm mattress, latex is probably not the right choice for you.

Conditions: Either a latex mattress or latex mattress topper is great for relieving back pain because they offer the best combination of comfort and support, Breus says.

Air Mattresses

We’re not talking about the blow-up mattresses you put your holiday guests on for a few days. Higher-end air beds look like a standard innerspring mattress, but use air-filled chambers instead of coils, and are covered by a foam layer on top.

Shamie notes that air beds have long been used for patients with spinal cord injuries who are lying in bed for a long time. They can be adjusted so they don’t continue to press on the same areas of the body, which helps to avoid skin breakdown in patients who can’t move.

Pros:"Couples who have dramatic differences in their individual preference for comfort and firmness levels might do very well with an air mattress," Breus says. The reason is that the firmness of each side of the bed can be altered. If you like it firmer than your partner, these beds can be adjusted for that.

Like latex and memory foam, you can also find air toppers for your mattress.

Cons:Shamie says people sometimes fail to make their air bed firm enough and wake up with back aches. Less sophisticated air mattresses also pop up on one side when you sit on the opposite end. For that reason Breus says, you want multiple chambers so that doesn’t occur.

Conditions:These beds are particularly useful when sleeping partners have different needs. If one of you has a bad back, one side can be made firmer than the other to provide greater support.

Continued

Adjustable Beds

These beds are able to bend and elevate at varying angles. As a result, the mattress has to be flexible. Different types of mattresses can be used on an adjustable bed – memory foam, latex, or air, for example. Spring mattresses are more difficult to use, however, because the springs don’t handle the bending well.

Pros:For people who have difficulty getting in and out of bed or who like to watch television in bed, Shamie says, adjustables can make life easier by moving you closer to where you need to be.

Conditions:If you suffer from sleep apnea, sleeping flat can make the condition worse by cutting off airways and causing the tongue to fall into the back of the throat, Shamie says. People who experience acid reflux can also benefit by sleeping in a bed that elevates their upper body.

Shamie also suggests adjustable beds for people with hip or back pain who have a hard time moving from a lying position to sitting up or standing.

Sofa Beds

When you have guests staying for a night or two, sofa beds come in handy. The mattresses in these beds tend to be very thin so they are flexible enough to fold and collapse into the couch. It’s a great convenience to have a sofa bed, but you’d be hard-pressed to find someone who raves about their comfort.

Pros:Sofa beds are convenient, especially if you have limited space. But from a health perspective, Shamie and Breus don’t see any advantages.

Cons:A night or two on a sofa bed is OK. But "this is probably the worst kind of bed you can sleep on long-term," Shamie says. The mattresses used in most sofa beds are very thin and the springs quite weak. "It really leads to an uncomfortable situation," Shamie says.

If you’re really tight for space and need a bed that folds up, Shamie says that futons, while not the most supportive, are better for your back than the typical sofa bed.

Conditions:There are no conditions for which a sofa bed will be helpful, according to the experts. But if you have a bad back or hips, these beds will be especially uncomfortable.

Continued

When to Part With Your Old Mattress

Today’s mattresses are made to last a lifetime. But you probably shouldn’t plan on keeping yours for that long. Our bodies change over time, Breus says, so the mattress that was once a joy to sleep on may no longer feel comfortable a few years down the road.

In addition, mattresses collect dust mites, fungus, and other germs that can exacerbate allergies and impact your sleep patterns. After 10 to 15 years, it’s time to think about buying a new bed.

Ultimately, the experts say that the best bed for you is the one that feels most comfortable. And remember, Shamie says, "There’s no mattress that’s going to save your body when you get only five hours of sleep." In order to feel your best, you need to get enough rest… no matter what type of mattress you’re sleeping on.

Sources

Arya Nick Shamie, MD, associate professor of orthopedic surgery and neurosurgery, Santa Monica UCLA Medical Center.

Breus, Michael, PhD, WebMD sleep expert and author ofBeauty Sleep: Look Younger, Lose Weight, and Feel Great Through Better Sleep

Kovacs, FM.The Lancet, November 2003; vol 362: pp 1599-1604.

Making the Perfect Mattress

Hand Crafted Comfort

The Puffy Mattress is the culmination of four years of research and development, foam formulations, and sleep trials. We believe, as do the majority of our customers, that we have crafted the perfect sleep system — especially for those with back pain.

It’s no secret that foam, especially higher quality foams such as those used in the Puffy, can only be compressed tightly for so long before degrading in quality. To ensure you receive your mattress in immaculate condition, we make, compress, and package our mattresses in smaller batches so they are only compressed for a week or two before you receive it.

Made the Right Way

100% Manufactured
in the USA

OEKO-TEX®️
STANDARD 100 CERTIFIED.

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