Not all reminiscence foam mattresses are created equally. Some are softer, whereas others are dense and supportive. Choosing the incorrect kind can have an effect on your sleep and trigger aches and pains, and never all reminiscence foam mattresses are as protected as they need to be. Some foams are made with poisonous chemical substances that you simply should not sleep on each night time, however fortunately, many manufacturers use protected foams of their mattresses. And certainly one of them opened its manufacturing facility doorways to present us a glimpse at how its foam mattresses are made.My fellow CNET mattress specialists and I had the chance to tour the 3Z model mattress manufacturing facility in Glendale, Arizona. During the tour of the 600,000-square-foot facility, we realized from the CEO how 3Z makes all of its beds — six distinctive manufacturers — in-house. Some of essentially the most well-known mattresses from 3Z embrace the Brooklyn Bedding Signature Hybrid, Helix Midnight Luxe, Leesa Sapira Chill Hybrid, Nolah Original 10-inch, Birch Natural and Bear Elite Hybrid. We got down to find out how a manufacturing facility that produces six manufacturers makes every mattress really feel distinctive and what meaning for you, the client. Read extra: Best Mattresses of 2025How does foam differ? Dillon Lopez/CNETOne of the first causes a mattress might really feel completely different from one other is the kind of foam used. For instance, the Tempur-Pedic Breeze Pro mattress feels drastically completely different from the Nolah Original 10″. While the Medium model of the Breeze Pro is also slightly 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 at the 3Z factory). This type of foam is lighter and more forgiving — meaning that it doesn’t leave you feeling like you’re stuck in the mattress. Poly foam is still pressure-relieving, but it makes you feel like you’re sleeping more on top of the mattress than too within it. All-foam beds, like the Nolah Original, are constructed with multiple layers of foam — each slightly different. Some foam layers are firmer and used for support, while others are comfort layers and allow for pressure relief. The chemical makeup of the foam determines its density, firmness and feel. What are the different types of foam used in mattresses?Besides polyurethane foam, other different types of foam include:Memory foamGel memory foamCopper-infused foamHigh-density foamLatex foamRead more: Guide to Mattress Types: Materials and What to ConsiderHow is foam made?Believe it or not, making foam is a similar process to making a cake. In short, you add the ingredients, mix and watch as the product rises. While the chemistry behind foam isn’t quite as simple as baking, this analogy breaks down the foam pouring process in easy terms. When Owen and I observed the process, it felt like we were in a How It’s Made episode. We were as close as someone could get; we quite literally could have reached out and touched the liquid pouring onto the conveyor belt. In layman’s terms, John Merwin, 3Z’s CEO, describes the foam pouring process as “mixing liquid chemical substances in exact ratios.” Once these chemicals are combined, they react and rise as the foam is carried down a conveyor belt. Dillon Lopez/CNET”This combination is fastidiously monitored to make sure uniformity and high quality because it rises and cures right into a stable foam block,” Merwin says. While it takes only mere minutes for the new foam to rise, it takes several hours to fully cure. Once the foam is solid, it’s then cut into exact layers to be used in any of 3Z’s mattresses. If you, like me, thought that the color of a foam determined its feel… that’s actually false. At the factory, we were told that the reason one piece of foam is gray, for example, and another is blue is to simply tell them apart. It’s also important to note that 3Z’s foam is CertiPUR-US certificated. This means that the foam is safe, fiberglass-free and made without toxic chemicals such as “ozone depleters, formaldehyde [or] heavy metals.” It also means that the foam with this certification “meets stringent requirements for content material, emissions, and sturdiness,” Merwin says. The only other foam certification is GOLS (Global Organic Latex Standard), but this only applies to latex foam. 3Z does have beds that contain GOLS latex foam (i.e., the Birch Natural), but that isn’t made in-house. The process of making latex foam is very different from polyurethane pouring; it requires certain raw materials, specific procedures and machinery. Video: Foam pouring at the 3Z mattress factoryWatch my fellow mattress expert, Owen Poole, and me explore the 3Z factory and understand how they make its foam. 3Z mattress foam Dillon Lopez/CNETI have tested more than 70 mattresses over the years, and some of the beds from 3Z are among my favorites. I largely credit that to the materials it uses; mainly the foam. 3Z is unique in that not many mattress brands in the US pour their own foam or, let alone, own a factory that makes its beds in-house. Merwin says, “Our foams are crafted with meticulous care and a focus to element. What units our foam aside is that it is poured in-house, giving us full management over the standard of the ultimate product.” He continues, “This additionally permits us to create new foam variations which are unique to our manufacturers.”Prior to the trip, Poole and I were very interested to know how 3Z makes their beds distinctive if all the assembled materials are coming from the same place. To this, Merwin says, “The distinction in really feel amongst them is because of various formulations and densities tailor-made to every mattress mannequin. We regulate the composition and construction of the froth to realize particular ranges of firmness, help, and luxury to satisfy every mattress’s distinctive necessities.”While 3Z makes a few “common” foams used in multiple beds and brands, Merwin says that “many of the foam we pour is tailor-made to every model,” and “every of our manufacturers has a definite id… [that] is supported by means of the supplies used to craft every model’s assortment of mattresses.” I walked away from my tour of the factory with both a better understanding of foam and how it impacts the feel and firmness of your mattress. Why this should matter to you Dillon Lopez/CNETIf you aren’t in the mattress industry like me, watching someone pour foam might not sound like a well-spent afternoon. However, if you value a premium and quality mattress, the making of your bed’s materials still applies to you. When looking for a new mattress, make sure its foam is Certi-PUR US certified to ensure your bed is free from toxic chemicals. Secondly, the type of foam in your mattress determines the feel and firmness. If you’re looking for pressure relief but are a hot sleeper, I recommend gel memory foam. However, if you enjoy the feel of traditional, dense foam, I recommend memory foam beds. Neutral polyurethane foam is a middle ground that seems to please most sleepers. If you purchase a mattress from 3Z, you can rest assured that the foam is made in-house, without harmful chemicals and designed specifically for comfort and support. Merwin says, “We are continually innovating and growing new forms of foam that set new benchmarks within the bedding trade.”Memory foam FAQs What is the principle ingredient in reminiscence foam? The foremost ingredient in reminiscence foam is usually petroleum. Technically, foam is manufactured from two chemical substances: di‐isocyanates and polyols. The foam course of begins by mixing these two chemical substances exactly in a pre-calculated ratio for a desired density. How dangerous is reminiscence foam for the setting? Memory foam is artificial, non-biodegradable and laborious to recycle. Additionally, the supplies of froth, reminiscent of petroleum, should not sustainable. What is the drawback of reminiscence foam? The largest drawback of reminiscence foam that I’ve discovered is how nicely it holds onto physique warmth. My mattress has reminiscence foam layers, and I like how this materials feels once I sleep on my facet. However, the fabric does warmth up. If you’ve gotten a reminiscence foam mattress, I like to recommend utilizing cooling bedding and cooling pajamas.
More