Around the world, many luxury mattress brands are built by hand in small factories by artisans of the trade, craftsmen who literally still make one bed at a time. The process of hand tufting is to mattress making what dovetail drawers are to cabinetry, hand carving is to furniture or hand stitching is to wallets, handbags, and clothing. Hand tufting has real advantages. The tufting process creates a distinctive resilient supportive feel and also prevents the layers in the mattress from bunching developing valleys. The hand tufting process compresses the mattress layers, driving long needles with ribbon binding tape through them, securing these tufts with rosettes on the top. Tufting a mattress by hand is neither the fastest nor cheapest way to make a mattress. Tufting a mattress by hand is both laborious and time consuming. Tufting a mattress by hand adds more people to the process of making a mattress, more equipment to a mattress factory and slows down how many mattresses can be built in a day dramatically. What was once common to all mattresses is now a lost art due to speed and cost controls.
There was once a standard in the furniture industry referred to as “furniture grade” foam. It was foam that was at least 1.8 pound density foam. In the last twenty years, few mattresses use furniture grade foam. In fact, it is more likely that mass produced mattresses use an abundance of 1.5 or 1.2 pound density foam. Posh Mattresses exclusively use Natural Latex Rubber, 3.0 pound density foam and 2.0 pound density foam. We believe we are the only mattress manufactured in America with every foam component greater than furniture grade. Knowing the density of foam in a mattress is critical if you are buying a mattress. Higher density materials mean more inherent material in the component and a greater material and component cost. Higher density foam is known for its longevity, shape retention, comfort, and performance. Lower density foam is known to sag, quickly break down and have a shorter lifespan.
Many mattresses over $2,000 in the US are built in large-scale factories owned by billion-dollar companies, private equity firms from New York, public brands you can find on the New York Stock Exchange or have been absorbed by international mattress companies from all over the world. These large companies and factories make one hundred-year-old brands your parents knew, online start up brands they acquired in the last decade that you saw on Facebook five years ago and even the older, best of the best, legacy luxury mattress brands that were once small and quaint whose names were of the founders of the business and pioneers to the mattress industry. These large companies and factories make all sorts of mattresses at many price points. Five-hundred-dollar mattresses are built in the same factories as those that make $1,000, $ 2,000, $5,000, and even $10,000 mattresses. Not only are all those different price point mattresses built in the same factories, but on the same “lines,” with the same robotics and by the same people. Our opinion is they do a great job. There can be nothing easy about that complexity.
Our company is a relatively small private company. And we can build luxury mattresses the way they used to be built, by hand with denser materials. We do it because we love the mattress business and because you deserve to get a lot when you spend a lot for your new mattress.
