Factory Tour: Mattress Making Steps

Welcome to our Dream Factory!

Our beautiful factory is the unique vision of our CEO John Merwin. We recruit the best talent in the USA, we provide hot, delicious, and discounted meals daily, and we are one of the best mattress factories for competitive salaries.

Our Dream Factory begins with respect—which is why John insists that machines do the heavy lifting, so that our craftsmen can focus on their craft.

Since our founding in 1995, John has worked tirelessly to bring together the best technology and the best craftsmen to create the most comfortable mattresses in the world.

Our Dream Factory is huge (we are talking more than 11 football stadiums huge), but each employee plays a significant part in the success of our company. We want to show you the amount of organization, hard work, and passion that goes into making your custom-made mattress.

Let’s get started!

Sewing is all about getting it right the first time—the precise measurements, stitching, and quality of work by our large and hardworking team of seamsters ensures that we craft the perfect mattress each and every time.

Our team of sewers is an integral part of the process, so integral that this team outweighs our other departments by double. The team is large enough to meet the complex demands of our intricate mattress designs—and provide the detailed stitching that ensures a long-lasting design for maximum comfort.

One of the toughest jobs in the factory, these skilled craftsmen seal up your mattress with a durable, tight, and neat ribbon around the perimeter of your mattress. While other mattress facilities require their craftsmen to lift, flip, and wrangle heavy mattresses all day—we pride ourselves on keeping the fatigue factor low in order to keep production, quality, and employee retention rates high.

We differentiate ourselves by using high-tech machinery and conveyor belts to move our mattresses so that our craftsmen can focus more on their craft—and even more on your long-lasting comfort. With our walk-around method, a taper can complete a mattress in exactly one minute and 15 seconds!

The bedrock of a great hybrid mattress is the coil core. In our case, we refuse to use anything less than individually wrapped steel coils—and to get these perfectly precise coils each and every time, we trust no one. Instead, we make them ourselves.

Despite our doubters, we have successfully used cranes and specialized operating systems to accommodate 30 coil machines in 12 assemblies—speeding up production and delivering quality every time. Our Dream Factory is the ideal location to monitor and craft the ideal spring that creates perfect pressure relief, targeted contouring, and much-needed edge support.

When you build your own foam—you save customers money. Homemade foam means less transportation costs, more stable price points, and greater quality control. Plus, we get to be inventive. Before long, we’ll be producing never-seen-before comfort because we won’t have to rely on outsourcing. We can find new solutions for cooling, pressure relief, and more.

We proudly pour, proof, and cut our own foam. We bake 100 foot-long buns of foam, which are then cut to size and sent over to become part of the most comfortable mattresses in the world.

In just 30 seconds, our four mattress roll pack machines can take a fully crafted mattress and safely compress, roll, and wrap that mattress for easy shipping to your front door.

A conveyor belt brings the mattress to the roll pack machine, and once snuggly rolled and ready, the newly roll-packed mattress slides along a conveyor beltway into a waiting cardboard box. The box is sealed and scanned for tracking purposes before being placed in one of many waiting delivery trucks at our nearby loading docks.