mattress made

How Mattresses Are Made?

Purchasing a mattress for your home can be a big decision. After all, a lot of money goes into getting an ideal mattress for your space. The objective to find the best mattress is to ensure that you have the utmost comfort and peaceful sleep. However, it can be confusing to choose the right mattress from a wide range of mattresses available in the market. 

We often consider mattresses based on — the type of mattress, features, quality, and price range. But have you ever wondered on are mattresses made? 

History of mattresses

To understand, how are mattresses made these days, we need to understand how we started using a mattress in the first place. Mattresses originated in primitive times when early humans were using leaves, straws, and animal skins as foundations to sleep on. Based on the minimal pieces of evidence that researchers found, they noted that primitive human beings started using beds to protect themselves from the cold and to sleep comfortably on a softer surface. As our ancestors begin to move out of the nomadic life, their bed and furnishing also begin to develop accordingly. 

From the historical findings, we get to know that in ancient times, the bed played an important role in different cultures. The development of a bed is closely related to the modern-day mattress that we know. For those who could afford expensive furniture, the bed frames evolved over the years. But mattresses remained simple and uncomfortable — with lumpy cotton, horse tails, agricultural waste, or rags. These primitive mattresses were not only uncomfortable but also inconvenient when it comes to cleaning them. The inconsistent textures and poor quality of raw materials paired with agricultural waste made the perfect breeding ground for ticks, flies, dust mites, and rodents. They did have one distinct benefit, though: since they were produced at home from leftover agricultural products, they were inexpensive.

The earliest industrial mattresses were made out of inexpensive filling materials like rags from garment industries. Halfway through the 1800s saw the introduction of mattresses with reinforcing inner springs core, which was likely the single most important advancement in mattress design. The development of the innerspring mattress led to the development of the foam mattress that we use nowadays. The innovation in design and use of high-quality material has completely changed the earliest mattress into a more superior and durable product.

The manufacturing process of a mattress: 

The mattress industry uses both natural and synthetic raw materials to manufacture mattresses. Different type of material is used to make different types of mattresses — innerspring, helical, memory foam, HR foam, latex, and natural latex foam. The core of a mattress can comprise of number wires or springs, natural fiber foam, polyurethane foam, and polyester. The topmost layer that covers the mattress from the outside is usually made of fabric such as polyester, cotton, and bamboo. 

Manufacture techniques for memory foam:  

  1. In the first step, isocyanates and polyols are mixed together with reacting agents.
  2. To create the foam this mixture then goes through a machine that froths the liquid into foam.
  3. The foam is then infused with gas or blowing foam to increase its density.
  4. Once the foam cools down, it is reheated and left out to cure. 
  5. After a couple of days, the foam is washed and dried to ensure the highest quality. 
  6. The foam is cut into pieces for mattress construction – king mattress size, small double mattress, single mattress size, etc.

Construction of a memory foam mattress

A memory foam mattress is made of polyurethane as the base layer. Additional padding layers are implemented on top of the base if needed. Each manufacturer constructs the foam in a different density, size, and thickness depending upon their standards. Livpure uses advanced 3D computerized technology to build multiple layers and pressure relieving zones to maximize comfort. The type of glue used varies depending on who builds the bed, however, manufacturers frequently utilize it to secure one layer to the next. These layers enhance the sleep experience by offering the right amount of support and motion isolation. 

Memory foam is known to trap heat easily, therefore advanced engineering used in Livpure Mattresses ensure high breathability and higher open cell with Aeroscape technology. In addition to that, some of our mattresses also feature Biocrystal technology which has been embedded into the mattress. 

The mattress is fitted in a removable fabric zipper cover that makes it super convenient to use and clean on a daily basis. This fabric cover is made out of high GSM premium material to ensure softness, durability, and long-lasting freshness. 

Final thoughts

Understanding the manufacturing process and assembling of a mattress tells you a great about your mattress. Over the years, mattresses have undergone several changes to be comfortable, supportive, and budget-friendly at the same time. The progress in the mattress industry is that there’s a lot more to look forward to in sleep innovation. The mattress of today focuses on your wellness as well as comfort. If you are looking for yourself or your family, check out the best mattress in India here

We hope you liked our article on how mattresses are made. Have a question for us? Drop your feedback and suggestion in the comments section for us. We would be happy to answer any questions.