Not all beds are made the same way. We went behind the scenes to see how the foam in your mattress is created

The type of foam your mattress is made of can affect not only your overall sleep quality, but it may also affect your overall health. Some foams are made of Toxic chemicals You shouldn’t sleep every night. Fortunately, many mattress brands make and use non-toxic foams in their mattresses. Here’s what to look for when shopping Non-toxic mattresses And why it should matter to you.

CNET’s sleep team had the opportunity to take a tour Brand 3Z Mattress manufacturer in Glendale, Arizona. During our tour of the 600,000-square-foot facility, we learned from the CEO how 3Z manufactures all of its beds—six unique brands—in-house. Some of the most popular mattresses from 3Z include Brooklyn Signature Hybrid Bedding, Helix Midnight Lux, Lisa Sapira Chill Hybrid, NOLA ORIGINAL 10 INCH, Natural birch and Elite hybrid bear. We set out to find out how the factory, which produces six different brands, makes each bed look special.

Read more: Best mattresses of 2024

How is foam different?

One of the main reasons why a bed may be 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″. While the mid-range model of the Breeze Pro is a little firmer than the Nolah Original, Tempur-Pedic uses dense memory foam in its mattresses. The foam in the Nolah Original is neutral polyurethane foam (made in 3Z Manufacturer).This type of foam is lighter and more forgiving – meaning it doesn’t make you feel like you’re stuck in the mattress. Polyester foam still relieves pressure, but It makes you feel that you are sleeping on top of the mattress more than inside it.

All foam beds, like the Nolah Original, are made from multiple layers of foam — each a little different. Some foam layers are firmer and are used for support, while others are comfort layers and allow for pressure relief. The chemical composition of foam determines its density, hardness and texture.

What are the different types of foam used in mattresses?

Besides polyurethane foam, there are various other types of foam including:

• Memory foam
• Gel memory foam
• Copper filled foam
• High density foam
• Latex foam

Read more: A guide to mattress types: materials and what to consider

How is foam made?

Believe it or not, making foam is a similar process to making a cake. In short, you add ingredients, mix, and watch as the product rises. While the chemistry behind foaming isn’t quite as simple as baking, this analogy breaks down the foaming process in easy terms.

As Owen and I watched the process, we felt like we were in the loop of how it’s made. We were as close as anyone could get; We could literally reach out and touch the liquid flowing down the conveyor belt.

In layman’s terms, John Merwin, CEO of 3Z, describes the foam casting process as “mixing liquid chemicals in precise proportions.” Once these chemicals are combined, they react and rise when the foam is transported through the conveyor belt.

“This mixture is carefully monitored to ensure uniformity and quality as it rises and cures into a solid, foamy mass,” Merwin says. While the new foam only takes a few minutes to rise, it takes several hours to fully cure. Once the foam is solid, it is cut into specific layers for use in any of the 3Z mattresses.

If you, like me, think that the color of the foam determines its texture… that’s actually not true. At the factory, we were told that the reason one piece of foam was grey, for example, and another was blue was simply to differentiate between them.

It’s also important to note that 3Z foam is present Certipur-United States Certified. This means the foam is safe, fiberglass-free, and made without toxic chemicals like “ozone depleters, formaldehyde (or) heavy metals.” It also means that foam with this certification “meets stringent standards for content, emissions and durability,” Merwin says.

The only other foam certification is Jules (Global Organic Latex Standard), but this only applies to latex foam. The 3Z has beds that contain GOLS latex foam (eg Natural birch), but this is not done at home. The process of making latex foam is very different from the polyurethane molding process; It requires specific raw materials, specific procedures and machines.

Video: Foam molding in a 3Z mattress factory

Watch my fellow mattress expert, Owen Paul, and I explore the 3Z factory and understand how they make their foam.

3Z mattress foam

I’ve tested more than 70 mattresses over the years, and some of the beds from 3Z are among my favorites. I attribute this largely to the materials he uses; Mainly foam.

3Z is unique in that there aren’t many mattress brands in the United States that infuse their own foam, much less have a factory that manufactures the beds in-house. “Our foams are manufactured with great care and attention to detail,” says Merwin. “What’s special about our foams is that they are poured in-house, giving us complete control over the quality of the final product.” “This also allows us to create different foam shapes that are exclusive to our brands,” he continues.

Before the trip, Paul and I were very interested to see how 3Z would make their beds special if all the materials assembled came from the same place. For this reason, Merwin says: “The difference in feel between them is due to the different compositions and densities designed specifically for each mattress model. We adjust the composition and structure of the foam to achieve specific levels of firmness, support and comfort to meet the needs of each mattress. Unique requirements.”

While 3Z makes a few “universal” foams used in a variety of beds and brands, Merwin says that “most of the foam we pour is tailored to each brand,” and “each of our brands has a distinct identity… (and that) Powered by the materials used to craft each brand’s mattress range.”

I came away from my factory tour with a better understanding of foam and how it affects the feel and firmness of a mattress.

Why should this matter to you?

If you’re not in the mattress industry like me, watching someone lather up may not seem like an afternoon well spent. However, if you value a premium, high-quality mattress, the craftsmanship of your bed materials still applies to you. When looking for a new mattress, make sure it has good foam CERTi-PUR US Certified to ensure your bed is free of toxic chemicals.

Second, the type of foam in your mattress determines its feel and firmness. If you are looking for stress relief but sleep hot, I recommend it Gel memory foam. However, if you enjoy the feel of traditional, dense foam, I recommend it Memory foam beds. Neutral polyurethane foam is a compromise that seems to satisfy most sleepers.

If you purchase a mattress from 3Z, you can rest assured that the foam is made locally, without harmful chemicals and specifically designed to provide comfort and support. “We are constantly innovating and developing new types of foam that set new standards in the bedding industry,” says Merwin.