All the materials used are locally sourced and arrive daily at our factories loading docks.
Seamstresses and Tailors work continuously throughout the day knitting fabrics, sewing borders, cutting to size, and carefully prepping all the fabrication for the mattress build.
The build starts with it’s core support system. It can either be a pure foam core without a spring or a traditional core with a spring depending on style of mattress.
We then apply the side and corner support around the springs / foam core. This ensures proper support around the sides and edges of every mattress.
The comfort layers are then carefully placed on top of the support system. This is where the layering of latex / memory foam / gel foam / nano coils / etc would be applied. This is a very tedious and controlled process which is vital to the overall comfort of each mattress.
After completion of the comfort layers, we then apply the top padding / stuffing of the mattress. The options could range from organic cotton stuffing, wool batting, or even thin layers of Cool Gel memory foam. This top layer ranges vastly between all models.
The next phase is the upholstery phase. This is where our fabrics are properly fitted for each mattress. The side fabric, top fabric, and bottom fabric all get knitted properly together for a snug and accurate fitting.
After the fabric is all set in place, we then send it to our tape edge process. This is where one of our craftsmen use a industrial size tape edge machine to bring each mattress together.
After the mattress has been completed. It goes through a specific quality assurance test, which requires approval by the factory foreman prior to being made available for sale.
The plastic is then applied to each mattress, with the proper labels and warranties being included.
11842 Jefferson Blvd
Culver City, CA 90230
(310) 744-5384
[email protected]