Specially designed forklifts bring the blocks from their designated rows to the machines for cutting.

The Vertical Machine cleans the skin off the sides of the big blocks (size: 45" H x 84"W x 102"L) and cuts them down to smaller sections according to a customer's needs.

Regular trade customers have given us patterns for the various shapes and sizes that are used in the production of the numerous styles that they make. The pattern is traced on the foam and cut accurately by skilled cutters to the exact shape of the cardboard pattern.

After a section has been cut from a bigger block it is taken over to the Horizontal Machine where the thicker piece (usually 35" to 45" thick, depending on grade) will be sliced down to a smaller thickness. This machine can be programmed to automatically slice any grade of flexible polyurethane foam from 3/4"to 45" thick and any increments in between.

The Angle Machine allows us to cut angles from 0 to 45 degrees. This machine is used to cut wedges for various applications. Remember, wedges are always cut in pairs from a bigger rectangular piece and have four dimensions ie. Cut from 2" on top to 4" on bottom x 15" high x 36" wide. You pick the dimensions and we will cut it for you.

The Contour Cutter uses a high-speed wire to cut foam into various shapes, curves or diameters. A wood template is mounted on the board and by following the shape of the template an identical version is cut into the foam at a specified length. This machine only cuts two-dimensional. The front and the back of the piece still remain flat.

Various thicknesses of polyester fibre can be cut and wrapped around foam cushions to give them a crowned or rounded look once they are stuffed into the fabric casing.

Foam and fibre are quilted into mattress fabrics to give a mattress a more comfortable look and feel. The mattress industry as a whole uses lighter weight grades for quilting foam; therefore, it is always better to keep the quilting in your cover to a minimum and go with a thinner mattress that is made with a heavier better density of foam.

Once the quilted fabric is cut to the required size the edges are surged together to keep the fabric from fraying. The sewn pieces are then passed on to the mattress closer.

The material is sewn around the mattress using a moving sewing machine that is known as a mattress closer. Mattress closing is used for the mass production of mattresses of the same size and grade for commercial applications. The better custom mattress manufacturers, that have nothing to hide, make removable covers with zippers that allow you to inspect the inside of the mattress and the option to make changes should the need arise.