I Got an Exclusive Look at How Mattress Foams Are Made

Not all memory foam mattresses are created. Some are softer, while others are dense and support. The choice of bad guy can affect your sleep and cause pain and pain, and all memory foam mattresses are not as safe as they should be. Some foams are made with toxic chemicals on which you should not sleep every evening, but fortunately, many brands use safe mosses in their mattresses. And one of them opened its factory doors to give us an overview of how its foam mattresses are made.

My colleagues experts in CNET mattress and I had the opportunity to visit the 3Z brand mattress factory in Glendale, Arizona. During the visit of the installation of 600,000 square feet, we learned from the CEO how 3z manufactures all its beds – six unique brands – internally. Some of the most famous 3z mattresses include the Brooklyn bedding hybrid, Helix Midnight Luxe, Leesa Sapira Chill Hybrid, Nolah Original 10 Inces, Birch Natural and Bear Elite Hybrid. We decided to learn how a factory that produces six brands makes each bed distinctive and what it means for you, the customer.

Find out more: Best mattresses of 2025

How does foam differ?

One of the main reasons why a bed may feel different from another is the type of foam used. For example, the Tempur-Pedic Breeze Pro mattress feels radically different from the original Nolah 10 “. Although the average model of Breeze Pro is also slightly firmer than the original of Nolah, Tempur-Pedic uses dense memory foam in its mattresses. Stuck in the mattress.

The whole -bad beds, like the nolah original, are built with several layers of foam – each slightly different. Some layers of foam are firm and used for support, while others are comfort layers and allow pressure relief. The chemical composition of the foam determines its density, its firmness and its sensation.

What are the different types of foam used in mattresses?

In addition to polyurethane foam, other different types of foam include:

• Memory foam
• Freezing memory foam
• Copper infused foam
• High density foam
• Latex foam

Find out more: Guide to mattresses: materials and what to consider

How is the foam made?

Believe it or not, the manufacture of foam is a process similar to the manufacture of a cake. In short, you add the ingredients, mix and monitor the product increase. Although chemistry behind the foam is not as simple as cooking, this analogy breaks down the foam payment process in easy terms.

When Owen and I observed the process, it was as if we were in an episode How It Made. We were as close as someone could get; We could literally have stretched the hand and touching the liquid pouring on the treadmill.

In simple terms, John Merwin, CEO of 3z, describes the process of payment of foam as “mixing liquid chemicals in specific ratios”. Once these chemicals are combined, they react and rise when the foam is transported in a treadmill.

“This mixture is carefully monitored to ensure uniformity and quality as it rises and heals in a block of solid foam,” explains Merwin. Although it only takes a few minutes at the new foam, it takes several hours to heal completely. Once the foam is solid, it is then cut into exact layers to use in one of the 3z mattresses.

If you, like me, thought that the color of a foam determined its feeling … It is actually wrong. At the factory, we were told that the reason why a piece of foam is gray, for example, and another is blue is to simply distinguish them.

It is also important to note that the 3z foam is certified certipur-US. This means that the foam is safe, without fiberglass and made without toxic chemicals such as “ozone exhaustors, formaldehyde [or] Heavy metals. “It also means that foam with this certification” meets strict standards for content, emissions and sustainability “, explains Merwin.

The only other foam certification is Gols (Global Organic Latex Standard), but this only applies to latex foam. 3Z has beds that contain latex gols mousse (that is to say the Birch Natural), but which is not done internally. The latex foam manufacturing process is very different from the polyurethane payment; It requires certain raw materials, specific procedures and machines.

Video: Foaming foam at the 3z mattress factory

Look at my colleague expert in mattresses, Owen Poole, and I explore the 3z factory and understand how they make its foam.

3z mattress foam

I have tested more than 70 mattresses over the years, and some of the 3z beds are among my favorites. I largely credit him to the documents he uses; mainly foam.

3Z is unique in that few mattresses in the United States pour their own foam or, even less, have a factory that makes its beds internally. Merwin says: “Our foams are made with meticulous care and attention to details. What distinguishes our foam is that it is paid internally, giving us total control over the quality of the final product.” He continues: “This also allows us to create new variations in foam which are exclusive to our brands.”

Before the trip, Poole and I were very interested in knowing how 3z makes their beds distinctive if all the assembled materials come from the same place. To this, Merwin says: “The difference in sensation between them is due to variable formulations and densities adapted to each mattress model. We adjust the composition and the structure of the foam to achieve specific levels of firmness, support and comfort to meet the unique requirements of each mattress.”

While 3z manufactures some “universal” foams used in several beds and brands, Merwin says that “most of the foam we pay is adapted to each brand” and “each of our brands has a separate identity … [that] is supported by the materials used to develop the mattress collection of each brand. “”

I moved away from my visit to the factory with a better understanding of the foam and its impact on the sensation and firmness of your mattress.

Why it should import you

If you are not in the mattress industry like me, watching someone pay foam may not look like an afternoon well spent. However, if you appreciate a premium and quality mattress, the manufacture of your bed materials always applies to you. When you are looking for a new mattress, make sure that its foam is certified Certi-Pur to make sure your bed is free from toxic chemicals.

Second, the type of foam in your mattress determines sensation and firmness. If you are looking for pressure relief but you sleep hot, I recommend gel memory foam. However, if you like the feeling of traditional and dense foam, I recommend memory foam beds. Neutral polyurethane foam is an common ground that seems to appeal to most sleeprs.

If you buy a 3z mattress, you can be assured that the foam is made internally, without harmful chemicals and designed specifically for comfort and support. Merwin says: “We are constantly innovating and developing new types of foam that have established new bearings in the bedding industry.”

FAQ in memory foam