Not all beds are made the same. Let’s go behind the scenes to see how the foam in your mattress is created

The type of foam that your mattress is made of can not only impact the overall quality of sleep, but it can also affect your overall health. Some foams are made with toxic chemicals who should not sleep every night. Fortunately, many mattress brands create and use non-toxic foam in their mattresses. Here’s what to look for when buying non-toxic mattresses and why it should be important to you.

CNET’s sleep team had a chance to visit brand 3Z mattress factory in Glendale, Arizona. During the tour of the 600,000-square-foot facility, we learned from the CEO how 3Z makes all of its beds — six unique brands — in-house. Some of the most popular mattresses from 3Z include Brooklyn Bedding Signature Hybrid, Helix Midnight Luxe, Leesa Sapira Chill Hybrid, Nolah Original 10-inch, Birch Natural and Bear Elite Hybrid. We began to learn how a factory that produces six different brands makes each bed distinct.

Read more: The best mattresses of 2024

How is the foam different?

One of the primary reasons that one bed can feel different from another is the type of foam used. For example, the Tempur-Pedic Breeze Pro Mattresses feels drastically 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 It’s made of neutral polyurethane foam (made in the 3Z factory). it still relieves the pressure, but it makes you feel like you’re sleeping more on the mattress than too much in it.

Foam beds, like Nolah Original, are built with several layers of foam – each slightly different. Some layers of foam are firmer and used for support, while others are comfort layers and allow pressure relief. The chemical composition of the foam determines its density, firmness and feel.

What are the different types of foam used in mattresses?

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

• Memory foam
• Memory foam gel
• Copper infused foam
• High density foam
• Latex foam

Read more: 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, add the ingredients, mix and watch as the product grows. While the chemistry behind foaming isn’t as simple as cooking, this analogy breaks down the foaming process in easy terms.

When Owen and I observed the process, it felt like we were in an episode of How it’s done. We were as close as anyone could get; We can literally touch the liquid pouring onto the conveyor belt.

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

“This mixture is carefully monitored to ensure uniformity and quality as it rises and cures into a solid foam block,” says Merwin. While the new foam only takes a few minutes, it takes several hours to fully heal. Once the foam is solid, it is then cut into precise layers to be used in any of 3Z’s mattresses.

If, like me, you think that the color of a foam determines its feel… it’s really false. At the factory, we were told that the reason that a piece of foam is gray, for example, and another is blue is only to distance them.

It is also important to note that the 3Z foam is CertiPUR-US certificate This means that the foam is safe, without fiberglass and made without toxic chemicals such as “ozone depleters, formaldehyde (or) heavy metals.” It also means that foam with this certification “meets strict standards for content, emissions and durability,” says Merwin.

The only other foam certification is OBJECTIVES (Global Organic Latex Standard), but this only applies to latex foam. 3Z has beds that contain GOLS latex foam (ie, the Birch Natural), but that is not done at home. The process of making latex foam is very different from polyurethane; it requires certain raw materials, specific procedures and machinery.

Video: Foam poured into the 3Z mattress factory

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

3Z mattress foam

I’ve tried over 70 mattresses over the years, and some of the beds from 3Z are among my favorites. I largely credit that to the materials he uses; mainly the foam.

3Z is unique in that not many mattress brands in the US make their own foam or, for that matter, own a factory that makes their beds in-house. Merwin says: “Our foams are handcrafted with meticulous care and attention to detail. What sets our foam apart is that it is poured in-house, giving us total control over the quality of the final product.” He continues: “This also allows us to create new foam variations that are exclusive to our brands.”

Before the trip, Poole and I were very interested to know how 3Z makes its distinctive beds if all the assembled materials come from the same place. To this, Merwin says: “The difference in feeling between them is due to the different formulations and densities adapted to each mattress model. Adjust the composition and structure of the foam to obtain specific levels of firmness, support and comfort to meet each mattress. unique requirements.”

While 3Z makes a few “universal” foams used in many beds and brands, Merwin says that “most of the foam we put out is tailored for each brand,” and “each of our brands has a distinct identity.. .(which) is supported by the materials used to create the mattress collection of each brand.”

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

Why this should be important to you

If you’re not in the mattress industry like me, watching someone pour foam may not sound like a good afternoon. In any case, if you value a premium and quality mattress, the manufacture of the materials of the bed is always applied to you. When looking for a new mattress, make sure that its foam is Certi-PUR US certified to ensure your bed is free of toxic chemicals.

Second, the type of foam in your mattress determines the feel and firmness. If you are looking for pressure relief but are a hot sleeper, I recommend it gel memory foam. However, if you like the feel of traditional, dense foam, I recommend it memory foam beds. Neutral polyurethane foam is a middle ground that seems to appeal to most dormitories.

If you buy a mattress from 3Z, you can be assured that the foam is homemade, free of harmful chemicals and specially designed for comfort and support. Merwin says, “We are constantly innovating and developing new types of foam that set new benchmarks in the bedding industry.”