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The type of foam your mattress is made of can not only affect your overall quality of sleep, it can also affect your overall health. Some foams are made with toxic chemicals that you don’t need to sleep every night. Fortunately, many mattress brands create and use non-toxic foams in their mattresses. Here’s what to look for when buying non-toxic mattresses and why it should matter to you.
CNET’s sleep team had a chance to take a tour 3Z brand Mattress Factory in Glendale, Arizona. During a 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, Helik Midnight Luke, Leesa Sapira Chill Hybrid, Nolah Original 10 inch, Birch Natural and Bear Elite Hybrid. We set out to learn how a factory that produces six different brands makes each bed distinctive.
Read more: The best mattresses of 2024
How is foam different?
One of the main reasons a bed can feel different from another is the type of foam used. For example, the Tempur-Pedic Breeze Pro Mattress feels drastically different from the Nolah Original 10″. While the Breeze Pro Medium model is also slightly firmer than the Nolah Original, Tempur-Pedic uses dense memory foam in its mattresses. The foam in the Nolah Original is a neutral polyurethane foam (made in the 3Z factory. This type foam is lighter and more forgiving — which means no it leaves you feeling like you’re stuck in the foam).
All-foam beds, like the Nolah Original, are made from multiple layers of foam – each one slightly different. Some layers of foam are firmer and are used for support, while other layers are for comfort and allow for 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 different types of foam include:
- Memory foam
- Gel memory foam
- Copper-infused 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 mousse is a similar process to making a cake. In short, you add the ingredients, mix and watch the product rise. Although the chemistry behind foam is not as simple as baking, this analogy breaks down the foam pouring process in a simple way.
When Owen and I watched the process, it felt like we were in an episode of How It Was Made. We were as close as anyone could be; we could literally reach out and touch the liquid that spilled onto the conveyor belt.
In layman’s terms, John Merwin, CEO of 3Z, describes the foam pouring process as “mixing liquid chemicals in precise proportions.” Once these chemicals are combined, they react and rise as the foam moves down the conveyor belt.
“This mix is carefully monitored to ensure uniformity and quality as it rises and hardens into a solid block of foam,” Merwin says. Although it only takes a few minutes for the new foam to rise, it takes several hours for it to fully cure. Once the foam is firm, it is then cut into the exact layers to be used in any of the 3Z mattresses.
If, like me, you thought that the color of the foam determined its feel… that’s actually incorrect. We were told at the factory that the reason why one piece of foam, for example, is gray and another is blue is just to tell them apart.
It’s also important to note that 3Z is foam CertiPUR-US certified. That means the foam is safe, fiberglass-free and made without toxic chemicals like “ozone-depleting, 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 GOALS (Global Organic Latex Standard), but this only applies to latex foam. 3Z has beds that contain GOLS latex foam (ie Birch Natural), but it is not made at home. The process of making latex foam is very different from polyurethane molding; it requires certain raw materials, specific procedures and machines.
Video: Foam is poured in the 3Z mattress factory
Watch my fellow mattress expert, Owen Poole, 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 3Z beds are among my favorites. I mostly attribute that to the materials he uses; mostly foam.
3Z is unique in that many mattress brands in the US do not manufacture their own foam or let alone own a factory that makes their beds in-house. Mervyn says, “Our foams are made with careful care and attention to detail. What sets our foam apart is that it is poured in-house, which gives us complete 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 find out how 3Z makes their beds stand out if all the assembled materials come from the same place. To this, Mervyn says, “The difference in feel between them is due to the different formulations and densities adapted to each mattress model.” We adjust the composition and structure of the foam to achieve specific levels of firmness, support and comfort to suit each mattress. unique requirements.”
While 3Z makes several “universal” foams that are used in multiple beds and brands, Merwin says that “most of the foam we pour is customized for each brand” and “each of our brands has a distinct identity … (that) is supported through materials that are used to create each brand’s mattress collection.”
I walked away from the factory tour with a better understanding of foam and how it affects the feel and firmness of your mattress.
Why should this bother you?
If you’re not in the mattress industry like I am, watching someone pour foam might not sound like an afternoon well spent. However, if you value a premium and quality mattress, the material construction of your bed still applies to you. When looking for a new mattress, make sure it’s foam 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 like to sleep, I recommend it gel memory foam. However, if you enjoy the feel of a traditional, thick foam, I recommend it memory foam beds. Neutral polyurethane foam is a medium that seems to appeal to most sleepers.
When you buy a 3Z mattress, you can be sure that the foam is made in-house, free of harmful chemicals and designed specifically for comfort and support. Mervyn says, “We are constantly innovating and developing new types of foam that set new benchmarks in the bedding industry.”
