The Building of a Mattress: What to look for!

The quilted cover of a mattress is made from a quilt that combines fabric, fire barrier, and foam. The quilted cover of a foundation is made, in part, from a quilt that combines fabric and fire barrier. The quality of fabric varies between the mattress groups, increasing in quality from the Good to Best groups.  We use damask fabrics made of polyester fibers. The fire barrier Mystic Mattress Maker uses is an untreated fiber that inherently resists flame.

The thickness and sewing pattern of a quilt affects the feel of the mattress. Generally, a small quilt pattern will feel firmer than a large quilt pattern that will have a plush feel. The quilted mattress cover is cut from a large roll and a flange is sewn around its edge. The flange is used to secure the cover to the innerspring.

The foundation cover is assembled by sewing a flame resistant filler cloth to a quilted
border cloth.

Quilting

Covers

Sewing by Hand

A Mystic mattress is assembled and finished by hand. A craftsman builds the body of a mattress by beginning with an innerspring and then adding layers of felt padding and foam. If edge supports are required, they are added at this time. Next, the mattress cover is placed on top of the body and secured to the innerspring.

The craftsman finishes the mattress by placing cushioning material in each of the four mattress corners and sewing a border to the mattress covers.

Adding the Layers

Taping the Edges

A foundation is a wood frame box built with pine lumber. A corrugated board is attached to the top and then finished with a cover.

A boxspring is manually assembled by securing individual coils to a grid and frame. A felt pad is added to the top of the grid and felt squares are inserted into the corners. The boxspring is finished by attaching a cover.

Making and Covering