How We Build Mattresses

Making Mattresses in Phoenix, AZ Since 1995

At Brooklyn Bedding, we've been building mattresses in Phoenix for more than 15 years. In that time, we've learned, refined, and improved our process to reach the peak performance and efficiency it's at today.

Inside our nearly 650,000-square-foot manufacturing facility in Arizona, raw materials become finished mattresses through a carefully planned process.

Because everything happens under one roof, we're able to stay close to the details, adjust quickly, and keep quality consistent from start to finish.

The Mattress Manufacturing Process

Here's how a mattress comes to life inside our facility, from first idea to final product.

Step 1: Start with the sleeper

Every mattress begins with a simple question: who is this for?
Different people need different things from a mattress. Some need more pressure relief, others need extra support, and many are looking for a balance of both. Some sleep hot. Some change positions throughout the night.

We start by understanding the sleeper’s needs, because that’s what shapes everything else.

Step 2: Turn the idea into a design

Once we know the problem we need to solve, we map out how to get there.

We think through how the layers should work together, how the mattress should feel, and how it should respond to weight and movement. Every detail is considered a crucial part of a bigger picture.

Step 3: Make the core materials

This is where things really start to get fun.

Inside our factory, we produce many of the key mattress components ourselves. That includes foam, from the initial mix to curing and cutting.

We also manufacture coil systems and handle our own cut-and-sew process for mattress covers.

By creating these components ourselves, we’ve eliminated reliance on outside suppliers for the most important elements of the mattress.

Step 4: Form and prepare each layer

Once materials are ready, they’re organized into the individual mattress layers.

Foam is cut into different sizes and thicknesses depending on purpose. Coils are shaped to deliver the right level of support and responsiveness.

Each layer has a distinct job, and this is when it’s ready to do it.

Step 5: Bring it all together

Then, the mattress moves into assembly.

Layers are stacked and combined in a specific sequence to match the original design. Materials move along a production line where each step builds on the last.

Since everything is happening in-house, the process maintains consistency from one mattress to the next.

Step 6: Finish, compress, and ship

The final steps prepare the mattress for its journey to your home.

Every mattress goes through a quality inspection before it’s compressed and packaged. Compression makes it easier to ship and deliver while also protecting the mattress’s structure and materials.

From there, it’s ready to ship.

Materials Sourcing and Certifications

What goes into a mattress matters just as much as how it's assembled.

We use a range of foams, coils, and textiles chosen for how they perform over time. Producing foam in-house allows us to oversee consistency and quality from the beginning.

Our facility is designed to support this kind of production, with the equipment and systems needed to safely handle and process materials at scale.

We also work with established standards and certifications that focus on safety and performance.

Certifications

Endorsed by the ACA

GREENGUARD Gold Certified

CertiPUR-US® Certified Foam

Quality Control

In our factory, quality assurance is part of the entire process. Starting from step one, we closely monitor key stages of mattress assembly in order to maintain the integrity of every product.

As mattresses move through production, dedicated teams confirm that each model matches its intended design. And before any mattress is considered "done," it goes through a final inspection.

This layered approach ensures the final product performs the way it's supposed to.

Why Manufacturing In-House Matters

Not every mattress company makes its own products—many rely on third-party vendors.

The Brooklyn Bedding approach is different.

By engineering our mattresses in-house, we are deeply familiar with every part of the process. That means we can:

Make improvements quickly
Keep materials and construction consistent
Respond to real-world feedback
Oversee how each mattress is made

This is a big part of how we work, as it gives us the flexibility to keep improving, without the limitations of following someone else's timeline.

What this means for you

A thoughtful and intentional engineering process allows us to create products that feel consistent, hold up over time, and do what they're designed to do: help you get better sleep.

Everything listed above comes down to how a mattress performs in your home. So far, we've succeeded at maintaining the highest standards of quality and have the reviews to prove it.