As the sleep editor, I frequently receive inquiries about mattress construction. The process varies significantly by mattress type, location, and budget.
Over my time overseeing the sleep category, I’ve toured three mattress factories: one in the United States and two in Sweden. I’ve explored a large, high-tech facility filled with machinery and a smaller, family-operated shop where artisans work by hand. I’ve engaged with materials like memory foam and horsehair, crafting mattresses that range from hundreds to tens of thousands of dollars.
Now, I’m excited to share insights from my visits. First, we’ll explore 3Z Brands in Glendale, Arizona, which manufactures Brooklyn Bedding, Bear, Helix, Birch, Leesa, and Nolah mattresses. Then, we’ll venture to Hästens in Köping, Sweden, where premium mattresses are handcrafted. Finally, we’ll peek into the IKEA Test Lab in Älmhult, Sweden, where mattresses undergo rigorous testing for comfort and durability.
Understanding Mattress Construction
To comprehend how a mattress is made, let’s first clarify the specific type of mattress. Here’s an overview of common mattress types and their materials, including some pros and cons.
Components of a Mattress
Modern mattresses typically consist of three layers: a support layer for weight distribution, a comfort layer for pressure relief, and a cover layer for protection. The specific materials depend on the mattress type. Here’s a brief introduction to some popular materials used.
- Steel coils: These coils are common in support layers and provide both responsiveness and stability, ensuring proper spinal alignment. Found in innerspring and hybrid mattresses, pocketed coils minimize motion transfer, a great feature for light sleepers.
- Memory foam: Crafted from polyurethane, memory foam's feel varies with density. High-density foam is firmer, suitable for support, while lower-density foam is softer, ideal for comfort layers. It excels in pressure relief and motion isolation but may trap heat, making it less ideal for hot sleepers.
When Jamie Davis Smith tested a memory foam mattress, she was hesitant until she experienced Nolah's unique AirFoam, designed for breathability.
For more insights, check our Nolah Original Mattress review.
Hybrid mattresses combine innerspring support with memory foam's pressure relief, offering a balanced experience. Hebe Hatton, our Head of Interiors, recently started using the Leesa Legend Chill and has been very pleased.
Stay tuned for our review of the Leesa Legend Chill Hybrid Mattress.
My sister has a Vesteröy mattress in her guest room, which I use during visits. It’s an excellent choice for back or stomach sleepers who prefer a firmer feel. Side sleepers may benefit from adding a mattress topper for added comfort.
- Latex: Latex production involves two methods. The Dunlop method creates firm latex for support layers, while the Talalay method produces softer, more breathable latex. Both processes require significant energy, resulting in higher costs for latex mattresses.
- Wool: Often found in comfort layers, wool is naturally thermoregulating and moisture-wicking. It can hold up to a third of its weight in moisture, making it an effective option for night sweats.
- Horsehair: This material is hollow, promoting breathability and thermoregulation. Sourcing and preparing horsehair is labor-intensive, which contributes to its cost.
During my visit to 3Z Brands, I sampled 43 mattresses. The Bear Natural stood out for its cool comfort, and I’ve been sleeping on it since June.
For more information, see our Bear Natural Mattress review.
Health-conscious sleepers, like our News Editor Sophie Edwards, appreciate natural materials for their comfort and thermoregulation benefits.
Read more in our Woolroom Hebridean 3000 Mattress review.
I had the chance to experience the Hästens Maranga Mattress during a night at Stallmästaregården Hotel in Stockholm. It was softer than I typically prefer but provided excellent support.
For details about the Maranga Mattress, check my account of the Hästens factory tour.
Crafting Mattresses on the Factory Floor
The 3Z factory operates as a vertical manufacturing plant. “We create our own materials, pour foam, and assemble beds,” explains John Merwin, CEO of Brooklyn Bedding and my guide. The facility spans 650,000 square feet and produces 2,200 mattresses daily across six brands, with potential to reach 4,000 at full capacity.
During the tour, we moved through various stations to observe the mattress-making process. First, seamstresses craft the mattress cover using industrial sewing machines. Concurrently, foam is tailored for specific sleep needs: some for responsiveness, others for pressure relief. The foam is poured into molds, expands, and solidifies into what John calls a ‘loaf.’ Once 100 feet of foam is ready, it’s cut and cured in the desert heat before stacking for storage.
At the same time, steel coils are formed into springs. Each coil is individually wrapped to enhance motion isolation, ensuring pressure on one coil doesn’t affect the others. Finally, all components are assembled and packaged for shipping.
In Köping, the Hästens factory operates on a smaller scale with around 80 artisans. Most tasks are done manually, emphasizing craftsmanship over machinery. I participated in the process and learned how much skill goes into making a mattress by hand.
For box mattresses, packaging is crucial. At 3Z, foam layers are glued, compressed, and vacuum-sealed to keep them airtight. The rolled mattress is then placed in a cardboard box for home delivery.
Although many mattresses today are box models, Hästens focuses on tradition. Their mattresses are wrapped in protective plastic, with custom boxes built around each mattress section, delivered in two parts, requiring physical effort to move into the home.
Testing Mattresses in the Lab
Before a mattress enters production, a prototype undergoes extensive testing. In the IKEA Test Lab's Comfort Suite, I observed this process firsthand, laying on a mattress connected to a computer.
“When testing a mattress, we focus on three areas,” says Susanna Wadensjö, a Test Development Engineer. “Pressure relief, indentation, and microclimate.” The goal is a mattress that balances comfort and support, soft enough for cushioning while maintaining spinal alignment and preventing sagging.
As I lay on the mattress, Susanna measured my pressure points, generating a thermal map to visualize data. She explained how distribution of materials may be adjusted based on where weight is concentrated.
To assess thermoregulation, Susanna introduced Ove, a device that simulates heat and moisture. This generated another thermal map showing the mattress's ability to dissipate heat, ideally appearing predominantly blue without hidden heat pockets that could disrupt sleep.
Before market release, mattresses must demonstrate comfort, support, breathability, and durability. Fredrik Lennartsson, another Test Development Engineer, operates a stress-testing machine that simulates years of use.
The IKEA Rollinator applies 1400N of force, replicating the pressure of an average adult moving across a mattress. It runs for five hours, completing 30,000 rolls, simulating a decade of nightly use and supporting IKEA's 10-year warranty.
“I aim to push mattresses beyond their limits,” Fredrik states. “I want to discover when and how they fail, and what we can learn from that.”
Once a mattress passes lab tests and reaches the factory, it’s ready for real-world evaluation. Like the IKEA lab team, I focus on pressure relief, weight distribution, thermoregulation, motion isolation, edge support, and pricing. For more on our testing methods, refer to our expert guide.
