Not All Beds Are Made the Same. We Went Behind the Scenes to See How the Foam in Your Mattress Is Created
The type of foam used in your mattress not only affects your overall sleep quality, but it may also affect your overall health. Some foams are made with toxic chemicals You shouldn’t fall asleep every night. Fortunately, many mattress brands make and use non-toxic foam in their mattresses. Here’s what to pay attention to when shopping non-toxic mattress and why it matters to you.
CNET’s sleep team had a chance to visit 3Z brand Mattress factory in Glendale, Arizona. During a tour of the 600,000-square-foot factory, we learned from the CEO how 3Z manufactures all of its beds (six unique brands) in-house. Some of 3Z’s most famous mattresses include Brooklyn Bedding Signature Blend, Spiral Midnight Luxury Hotel, Leesa Sapira Chill Hybrid, Nora original 10 inches, natural birch and Bear Elite Hybrid. We set out to find out how a factory that produces six different brands makes each bed unique.
Read more: The best mattresses of 2024
How is a bubble different?
One of the main reasons one bed feels different from another is the type of foam used. For example, Tempur-Pedic Breeze Pro Mattress It feels very different from the Nolah Original 10″. Tempur-Pedic uses dense memory foam in its mattress, although the Breeze Pro’s mid-size is also slightly firmer than the Nolah Original. The foam in the Nolah Original is a neutral polyurethane foam (produced by 3Z Factory) This type of foam is lighter and more forgiving – meaning it won’t make you feel like you’re trapped in the mattress, but it will make you feel like you’re trapped in it. Sleep on the mattress more often than inside the mattress.
All-foam beds, like the Nolah Original, are constructed from multiple layers of foam, each layer slightly different. Some foam layers are firmer for support, while others are comfort layers for pressure relief. The chemical composition of foam determines its density, hardness and feel.
What are the different types of foam used in mattresses?
In addition to polyurethane foam, other different types of foam include:
- memory foam
- gel memory foam
- copper-infused foam
- high density sponge
- latex sponge
Read more: Mattress Type Guide: Materials and Considerations
How is foam made?
Believe it or not, the process of making foam is similar to making cake. In short, you add ingredients, mix and watch the product ferment. While the chemistry behind foaming isn’t as simple as baking, this analogy breaks down the foam pouring process in simple terms.
As Owen and I observed the process, it felt like we were watching a “How To” episode. Our relationship has reached its breaking point. We can literally reach out and touch the liquid being poured onto the conveyor belt.
In layman’s terms, 3Z CEO John Merwin describes the foam casting process as “mixing liquid chemicals in precise proportions.” Once these chemicals are combined, they react and rise as the foam travels along the conveyor belt.
“This mixture is carefully monitored to ensure uniformity and quality as it rises and solidifies into a solid foam block,” Merwin said. While the new foam takes only a few minutes to rise, it takes several hours to fully cure. Once the foam sets, it’s cut into precise layers for use on any of 3Z’s mattresses.
If you’re like me and think that the color of the foam determines how it feels…that’s actually wrong. For example, at the factory we were told that one piece of foam was gray and another blue, just to differentiate them.
It’s also important to note that 3Z’s foam is CertiPUR-USA Certified. This means the foam is safe, contains no fiberglass, and does not contain toxic chemicals such as “ozone depleters, formaldehyde (or) heavy metals.” Merwin said it also means foams that receive this certification “meet stringent standards for content, emissions and durability.”
The only other foam certifications are Target (Global Organic Latex Standard), but this only applies to latex foam. 3Z does have beds that contain GOLS latex foam (i.e. natural birch), but this is not made in-house. The process of making latex foam is very different from polyurethane casting; it requires certain raw materials, specific procedures and machinery.
Video: Foam pouring at 3Z Mattress Factory
Watch my fellow mattress expert Owen Poole and I explore the 3Z factory and learn how they make foam.
3Z mattress foam
I’ve tested over 70 mattresses over the years, and 3Z’s beds are some of my favorites. I attribute a lot of that to the materials it’s made from; mostly foam.
3Z is unique in that not many mattress brands in the United States pour their own foam, let alone have a factory that manufactures their own beds. “Our foam is crafted with care and attention to detail,” said Merwin. “What makes our foam unique is that it is poured in-house, giving us complete control over the quality of the final product.” He continued, “This also gives us Being able to create new foam varieties that are unique to our brand.”
Before the trip, Poole and I were curious to see how 3Z could make their beds special if all the assembly materials came from the same place. Merwin says: “The difference in feel between them is due to the different formulas and densities that are tailored to each mattress model. We tune the composition and structure of the foam to achieve specific levels of firmness, support and Comfort to meet every mattress’s unique requirements. “
While 3Z makes some “universal” foams for use across multiple beds and brands, Merwin says “most of the foam we pour is custom-made for each brand” and “each of our brands has The unique identity…(is) through the materials used to make each brand’s mattress range.”
After visiting the factory, I had a better understanding of foam and how it affects the feel and firmness of a mattress.
Why this matters to you
If you’re not in the mattress industry like I am, watching someone pour foam probably doesn’t sound like an afternoon worth spending. However, if you value a quality mattress, the material of the bed will still work for you. When looking for a new mattress, make sure its foam is US certified PUR Certified to ensure your bed is free of toxic chemicals.
Secondly, the type of foam in the mattress determines the feel and firmness. If you are looking for stress relief but sleeping hot, I recommend gel memory foam. However, if you like the feel of traditional dense foam, I recommend memory foam bed. Neutral polyurethane foam is a middle ground that seems to please most sleepers.
When you purchase a mattress from 3Z, you can rest assured that the foam is made in-house, contains no harmful chemicals, and is designed for comfort and support. “We continue to innovate and develop new foams that set new benchmarks in the bedding industry,” said Merwin.
