mattress companies source their materials

Where Do Most Mattress Companies Source Their Materials?


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Mattress toppers & pads are a great way to cool your bed and extend its life.
Topper SizeMaterialFirmnessWarr.
LINENSPA
LINENSPA 2 Inch Gel Infused Memory Foam Mattress Topper, Twin
Best Value2"Gel memory foamMedium3 years
MOLECULE AIRTEC
MOLECULE AIRTEC
Best Comfort3"Memory foamMedium-firm5 years
MyPillow
MyPillow Three-inch Mattress Bed Topper (Twin)
Best pressure point relief3"FoamMedium-firm10 years
LUCID
LUCID 2-Inch Ventilated Gel Infused Memory Foam Mattress Topper - Full
Best cooling2"Gel memory foamSoft3 years
Milemont
Milemont Mattress Topper Twin, 2-Inch Cool Swirl Gel Mattress Topper for Twin Size Bed, Blue
Best for back pain2"Gel memory foamMedium10 years
Pure Green
Pure Green 100% Natural Latex Mattress Topper - Firm - 2 Inch - Queen Size
Best for stomach sleepers2"Natural latexExtra-firm5 years
Sleep Innovations
Sleep Innovations 4-inch Dual Layer Gel Memory Foam Enhanced Support, King, Made in the US Mattress Topper
Best for side sleepers4"Gel memory foamSoft10 years
Sleep Number DUAL TEMP
Sleep Number DUAL TEMP
Best temperature regulation-Forced Air-1 year
TEMPUR ProForm
Tempur-Pedic TEMPUR Supreme 3-Inch Mattress Topper Medium Firm, Full, White
Best memory foam3"Memory foamMedium-firm10 years
Avocado Green
Avocado Green
Best organic2"Organic latexSoft/firm10 years
Bed cooling/heating systems have come a long way – especially the BedJet, my favorite.
SystemTypeBest For...Temp. RangeControl
BedJet V3
BedJet V3
Air cooledBEST OVERALL (esp. for night sweats)66°F-104°FWireless remote control/smartphone app
ChiliPad Cube 3.0
Chili Technology chiliPAD Cube 3.0 - ME and WE Zones - Cooling and Heating Mattress Pad - Individual Temperature Control, Great Sleep Enhancement, Wireless Remote Integration (Queen (80" L x 60" W))
Water cooledBest water cooling system55°F-115°FWireless remote control
Ooler Sleep System
Ooler Sleep System
Water cooledBest temperature control55°F-115°FSmartphone app via Bluetooth
The Pod by Eight Sleep
The Pod by Eight Sleep
Water cooledBest smart cooling system55°F-115°FSmartphone app/smart voice assistant
Mattress Cooler "Classic"
2020 Mattress Cooler "Classic" Chilled Water Sleep Cooling System (Now with a Spare "27x63" Cooling Pad)
Water cooledBest budget cooling systemN/AWireless remote control
SleepNumber Dual-Temp v3
SleepNumber Dual-Temp v3
Air cooledN/ARemote control
bFan Cooling System
bFan Cooling System
FanBest bed fanN/AWired remote control
Brookstone bed fan
Brookstone Bed Fan with Wireless Remote
FanN/AWireless remote control
These pillows excel at relieving neck and shoulder pain:
PillowWhy I Like It
PlushBeds Shredded Natural Latex Pillow
Best Cooling Mattress Pads

best shredded latex pillow for side sleepers
Coop Home Goods Memory Foam
Coop Home Goods - Premium Adjustable Loft Pillow - Hypoallergenic Cross-Cut Memory Foam Fill - Lulltra Washable Cover from Bamboo Derived Rayon - CertiPUR-US/GREENGUARD Gold Certified - Queen
perennial, proven Amazon Choice with over 16,000 reviews
MARNUR Contour Pillow
MARNUR Cervical Memory Foam Pillow Orthopedic Contour Pillows for Neck Pain Ergonomic Pillow with RoHS Certification and Pillowcase Covers, White(23.5×14.5×5.5 Inch)
perfect spine support using a groove down the middle
SleepRightSplintek Side
SleepRight Splintek Side Sleeping Pillow Memory Foam Pillow – Best Pillow for Sleeping On Your Side – 24" x 5" Standard Size
full facial cradle plus a perfectly-angled shoulder cradle
Xtreme Comforts Adjustable Pillow
Xtreme Comforts Hypoallergenic, Adjustable Thickness, Kool-Flow Micro Vented Bamboo Shredded Memory Foam Bed Pillow for Sleeping, Back, Stomach & Side Sleepers, Queen Size, Made in USA
thinner and softer than most, so your head will not bend back
UTTU Sandwich Pillow
UTTU Sandwich Pillow, Adjustable Memory Foam Pillow, Bamboo Pillow for Sleeping, Cervical Pillow for Neck Pain, Neck Support for Back, Stomach, Side Sleepers, Orthopedic Contour Pillow, CertiPUR-US
designed specifically for neck support and alignment.
Mediflow Water Pillow
Mediflow Fiber: The First & Original Water Pillow, clinically Proven to Reduce Neck Pain & Improve Sleep. Therapeutic, Ideal for People Looking for Proper Neck Support
clinical tests prove it reduces neck pain
Cradle Me Cervical Pillow
Cradle Me Cervical Pillow - Orthopedic Contour Memory Foam Pillow for Back and Side Sleepers with Neck and Spine Support - Helps Reduce Back and Neck Pain
best overall design with lots of position choices
KaUa Neck Roll
K Ka Ua Neck Roll Pillow Cervical Bolster with Bamboo Cover – Memory Foam Spine Lumbar Traction Spondylosis Support 4” Diameter x 17 “Length (4 Inch)
1,000s of satisfied customers & rave reviews
J-Pillow Travel Pillow
J-Pillow Chin Supporting Travel Pillow - 2020 Version - British Invention of The Year Winner - Supports Your Head, Neck & Chin (Blue)
added chin support prevents your head from falling forward.
EPABO Contour Memory Foam Pillow
EPABO Contour Memory Foam Pillow Orthopedic Sleeping Pillows, Ergonomic Cervical Pillow for Neck Pain - for Side Sleepers, Back and Stomach Sleepers, Free Pillowcase Included ( Firm & Queen)
Designed to support and cushion you neck and shoulders
J-Pillow Travel Pillow
AVOCADO GREEN PILLOW-Loveable non-toxic pillow has an adjustable fill, made from GOLS organic certified latex and GOTS organic certified kapok.
An all-natural, organic and vegan pillow with an adjustable loft to suit all sleeping positions
These are my favorite luxury sheet sets sold online:
Best Luxury SheetsIncludesSizesColours
Parachute
Parachute
Fitted sheet + two pillowcasesTwin to Cal KingSand, Slate, White, Light Grey, Blue
Brooklinen
Brooklinen Luxe Core Sheet Set – Includes 1 Flat Sheet, 1 Fitted Sheet + 2 Pillowcases – 480 Thread Count Sateen Sheet Set – 100 Percent Long-Staple Cotton – Oeko-TEX Certified – Smoke – Twin
One flat sheet, one fitted sheet, and two pillowcases.Twin to Cal KingWhite, Cream, Steel, Smoke, Smoke Stripe
Saatva
Saatva
One flat sheet, one fitted sheet, and two pillowcases.Twin to Cal KingWhite, Ivory, Grey
Boll and Branch
Boll & Branch Luxury Fair Trade Long Staple Organic Cotton Sheet Set - Full, Natural
one fitted sheet, one flat sheet, and two pillowcases.Full, Queen, King, Cal King onlyWhite, Solid Natural, Striped White, Pewter
Best For Specific Needs Soft and Warm: Parachute’s Sateen sheets Most Luxurious: Brooklinen’s Linen sheets Organic Luxury Sheets:  Saatva Lofton Organic sheets Breathable/Cool: Percale sheets from Parachute or Brooklinen
NOTE: We earn from qualifying purchases made via Amazon Associates and other affiliate programs. Learn more.

Have you ever wondered from where the mattress materials (foam, cotton, or springs) in your mattress come?

Are they sourced locally, or are they imported from China and does it matter?

In this post, we explain where most mattress companies source their materials and the difference it makes in mattress quality.


Does ‘Made In America' Mean Anything, Anymore?

made in America

A few years ago, before bed-in-a-box mattresses became popular, most mattress manufacturers sourced their products from China and other countries where manufacturing cost is low.

Most legacy mattress makers still do. But a growing number of companies have shifted to manufacturing their products locally, led by direct-to-consumer mattress brands like Casper and Leesa.

The main reason for this shift is to respond to market demand.

According to several polls, Americans want more ‘Made in America’ products even if they cost slightly more.

Most people cite preserving jobs, supporting local companies, quality issues, safety concerns, and environmental protection as their biggest reasons for buying American-made products.

But what does ‘Made in America’ exactly mean?

That depends on the company’s definition. Since there are no legal standards for putting that label on a mattress, companies can use it as they please.

Many mattresses with that label are made in America, and materials like foam and springs are sourced locally as well.

But other uses of that label are misleading. The mattress may have been assembled in the US, but the materials are sourced from other countries.

A good example is Casper. Mattresses are made in the US, but they get the components from abroad.

If you want a genuine ‘Made in America’ mattress, do your due diligence. Check where the company gets its materials and where the mattresses are assembled.


How Most Mattresses Are Made Today

Traditional innerspring mattress
Traditional innerspring mattress with connected coils

The earliest beds were made from a variety of natural materials like horsehair, straw, or feathers.

In the early 20th century, innerspring mattresses were invented. They became hugely popular thanks to their comfort, support, and durability.

Even today, innerspring mattresses are still highly popular.

But there are far more varieties than there were several decades ago. Memory foam beds have become especially popular because they are affordable yet very comfortable.

Most mattresses today use synthetic materials like memory foam and synthetic latex. Most also feature a multi-layer design with different materials in each layer.

The popular innerspring mattresses have also evolved.

Pocket coils are now widely used instead of Bonnell and Continous coils.

Additionally, the coil layer is combined with multiple layers of foams both at the top and below it to increase comfort, support, and longevity.

Direct to Consumer

Perhaps the biggest change that has occurred in the mattress industry is how mattresses reach customers.

With a traditional supply chain, mattresses start at the factory and pass through several intermediaries before reaching retail stores.

By the time you go to the store to pick a mattress, the price has gone up to cater for profit margins of all the intermediaries. Costs associated with transport, warehousing and stocking are also passed onto you.

Starting around 2010, companies like Saatva followed Tuft and Needle and later Casper changed the playbook.

They made mattresses in a factory and delivered them straight to customers. Most of these direct to consumer companies have no stores or warehouses. They sell their mattresses online.

This has drastically cut down on costs, savings that have been passed to customers.

Today, you can get a premium quality mattress for a fraction of the cost of a store-bought mattress with the added benefits of a long warranty (at least ten years) and a log in-home trial period.


Common Materials Used in Mattress Manufacturing

Common Materials Used in Mattress Manufacturing

The materials used in a mattress determine its comfort, longevity, and price.

An innerspring mattress feels markedly different from a memory foam mattress. A latex mattress sleeps differently from a poly foam mattress.

Here are the most common materials that makeup mattresses.

Memory Foam

Also referred to as viscoelastic foam, memory foam is one of the most common materials.

It is known for its ability to mold around the body and recover its shape when you wake up. That’s why memory foam mattresses are often recommended for people with back pain and joint aches.

The main downside of memory foam is that it retains heat. It can get uncomfortably warm at night.

Some companies add cooling gel to the foam to dissipate the heat more efficiently. Others perforate the foam to improve airflow.

Some memory foam mattresses feature a cool latex foam layer on top.

Latex Foam

Latex foam mattresses were around even before innerspring mattresses though they later fell in popularity.

These days, more people are buying them to enjoy their slightly firm and bouncy comfort.

Latex foam feels firmer than memory foam and doesn’t contour to the body as readily. It’s great for those who want more support.

It’s also great for sex because it is more responsive, meaning its bouncier.

Latex foam stays cooler than memory foam since it doesn’t retain heat.

There are two types of latex foam.

  • Synthetic latex. This is the most common. It’s used in the budget to medium cost latex mattresses.
  • Natural/organic latex. It’s expensive but has less of an odor than the petroleum-based synthetic latex.

Before you buy a latex foam mattress, check that you do not have latex allergy/sensitivity.

Polyurethane Foam

This is the cheapest type of foam for manufacturers to source so you’ll often find it in budget mattresses.

It is soft and contours to the body, but it’s not as comfortable as memory foam or as supportive as latex foam.

Because it is petroleum-based, there are also concerns about pollution and smells from volatile organic compounds (VOCs).

Polyester Batting

Polyester batting is a synthetic material used in pillow tops or mattress covers. It’s soft though it’s poor in cooling and absorbing moisture.

Wool

Wool is also used in pillow tops and mattress covers. Because it is natural (it’s gotten from sheep), it doesn’t have a strong odor and is hypoallergenic.

Wool is great for breathability. It allows body sweat and heat to evaporate, thus keeping the mattress cool, dry, and fresh.

Cotton

Cotton is used in the mattress cover in place of the cheaper polyester.

Cotton is soft, is great at absorbing moisture and keeps the surface of the mattress cool.

Most mattress manufacturers who use a cotton cover on their mattresses often opt for organic cotton. It’s healthier and hypoallergenic.

Adhesives

Adhesives are glues used to hold different components of the mattress together. You’ll often find adhesives between the layers of a mattress.

Modern mattress manufacturers are increasingly eschewing adhesives because of health concerns while others like Casper have shifted to the safer though pricier water-based adhesives.

Flame Retardants

By law, mattress and mattress pad manufacturers in the US must take measures to reduce the flammability of their products.

Manufacturers use flame-retardants, chemicals that make the mattress resistant to burning.

There are concerns about the health safety of these retardants with the Consumer Product Safety Commission (CPSC) going so far as to warn against certain types of retardants.

Modern mattress manufacturers are opting for non-chemical retardants like Kevlar and silica.

Steel Coils

Steel coils or springs in a mattress provide extra support and durability.

Pocket coils, the type of springs used in most mattresses today, also improve how well the mattress conforms to your body shape and curves, which increases pressure relief.

Steel coils in a mattress vary in terms of thickness, shape, and overall design. Some coils are designed solely for support while others increase the level of responsiveness.

Cooling Gel

This is a relatively new addition to mattresses. It’s often added in memory foam mattresses to enhance cooling.

Phase-change materials (PCMs)

You’ll also find these in memory foam mattresses. They are special cooling materials integrated into the cover or the mattress itself.

They maintain mattress temperature within a specific comfortable range. If you get too warm, they get cool. If you get too cold, they warm you up.

Spandex

Spandex is common in sports and athleisure wear. It’s stretchy and snuggles comfortably against the body.

In mattresses, spandex is used in the cover usually in combination with another fabric like polyester.

Spandex gives the mattress cover a nice stretchy feel.

Bamboo

If you get hot at night, look for a mattress with a bamboo cover. Bamboo is super soft, highly breathable and does a great job cooling the mattress.

It’s often used in combination with another fabric, usually polyester.


Where Do Mattress Companies Get Their Materials?

Leggett and Platt

It’s hard to pinpoint exactly where specific mattress companies get their materials because they don’t publish details.

Even if you called them, they’d probably hesitate to tell you.

But there are major suppliers of mattress materials who are well known.

Spring/Coil Suppliers

Leggett & Platt

Founded in 1883, Leggett & Platt was one of the earliest companies to introduce coils for mattresses.

Today, the company manufactures far more than just inner springs though they are still one of the biggest suppliers to mattress companies.

They supply several different types of coils including fabric-encased pocket coils, open coils, and edge support coils.

Hickory Springs

This is another major supplier of bedsprings. It was founded in 1944.

Their product line includes offset springs, box springs, fabric-encased pocket coils, and micro-coils.

They also supply fiber battings used on top of innerspring in a mattress, in pillow tops, and some mattress pads.

Foam Suppliers

There are plenty of foam suppliers that make different kinds of foam products from proprietary foams to the more common types like latex and poly foam. Here are a few of the major ones.

Carpenter: A major supplier of CertiPUR-US certified polyurethane foams. You may have come across some of their brand names when shopping for a mattress: Avela, Isotonic, Renew, Hypersoft, and Omalon.

FXI: FXI focuses on manufacturing environmentally friendly foams that are also safe for users. Their products include memory foam, gel-infused foam and poly foam. All their foams are CertiPUR-US certified.

NCFI: NCFI manufactures high-quality polyurethane foams. Their product line includes bio-foams that have a high level of recyclable components.

Latexco: Despite the name, Latexco manufactures more than just latex foams. They also supply poly foams and pocket coils. Their latex products include natural latex cores, synthetic latex cores, and blended (latex + springs) cores.

Talalay Global: Talalay Global is one of the biggest suppliers of natural Talalay latex. Their foam cores are made in the USA and are Oeko-Tex certified.

Arpico: Arpico is a Sri Lankan manufacturer that supplies Dunlop latex, a firmer and more durable type of latex compared to Talalay latex.

Covering all the suppliers in one list is impossible. There are so many of the spread out all over the world.

Mattress manufactures typically move among suppliers as they change and refine their products. They can also source the same materials from multiple suppliers to meet demand.


How To Ensure Your Mattress Is Safe and Non-Toxic

How To Ensure Your Mattress Is Safe and Non-Toxic

  • Go with certified organic or natural mattresses. These mattresses have fewer chemicals, making them much safer for your health and the environment as well.
  • Look for a mattress with an organic cover if an organic mattress is too expensive, compromise and get a synthetic mattress with an organic cotton cover. It’ll be better for your skin and will feel more comfortable.
  • Only buy mattresses with quality certifications. For memory foam and polyfoam mattress, look for the CertiPUR-US certification. For organic latex mattresses look for the GOLS certification.
  • Buy ‘Made in the USA’ mattresses. A mattress manufactured in the USA has undergone a more rigorous quality assurance process. It’s unlikely to contain harmful chemicals and will have better fire protection compared to mattresses shipped from abroad.
  • Avoid mattresses with chemical fire retardants.
  • Avoid dirt-cheap mattresses. A $200 queen size mattress is likely made with low-quality foams containing toxic chemicals like fire retardants and adhesives. Most online mattress companies provide easy, and sometimes interest-free, financing options, so it’s easy to buy a good quality mattress without draining your bank account.

 


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