How a mattress is made
Raw Materials
Mattresses are presently made of many materials, both natural and synthetic. The innerspring, helical, and boxspring components are made from wire; the boxspring wire is usually of a heavier gauge than that used in the innerspring. The insulator consists of semi-rigid netting or wire mesh, and the cushioning layers can comprise a number of different materials including natural fiber, polyurethane foam, and polyester. The flanges are made of fabric, and the hogs rings of metal. Top, bottom, and side panels consist of a durable fabric cover quilted over a backing of foam or fiber, and the binding
Once the completed innerspring unit is received, workers manually apply the insulator. Next, they apply the cushioning layers that will determine the feel and comfort of the final product. Meanwhile, the decorative cover that will serve as the exterior for the top, bottom, and sides is made on a giant quilting machine, which controls a multitude of needles that stitch the cover to a layer of backing material.
tape that holds the ticking together is made of heavy-duty, fibrous, synthetic material. The underlying boxspring may consist of either a wooden frame with slats or of metal coils similar to those used in the mattress itself. The boxspring may be upholstered, but, even if it is not, it always receives a fabric covering.
The Manufacturing
Process
Building mattress layers
• 1 Most mattress manufacturers subcontract the production of the innerspring unit to an outside firm that specializes in making springs. Once the completed spring unit is received and inspected, the workers manually apply the insulator. Next, they apply the cushioning layers that will determine the feel and comfort of the final product.
• 2 While the mattress is being “built up” in one part of the plant, the decorative cover that will serve as the exterior for the top, bottom and sides is being made in another part. Usually this cover is made on a giant quilting machine, which controls a multitude of needles that stitch the cover to a layer of backing material. The stitching chosen serves both useful and ornamental purposes, as it must prevent the mattress cover from slipping or creeping over the layers of cushioning in addition to creating a visually pleasing exterior.
• 3 Once the fabric is quilted, it is cut into panels that will fit the top and bottom of the mattress. The side panels are often cut from this same composite or made separately on a border machine. If side handles or vents are to be added, they are attached to the side panels before these are applied to the mattress.
Attaching the flanges
• 4 Specially modified sewing machines are used to attach the flanges to the top and bottom panels, and the hogs rings are stapled to the flanges. Everything is now ready for the closing operation, during which the hogs rings will be secured to the innerspring unit.
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