How are latex mattresses made?

How are latex mattresses made?

Latex mattresses are made from a product called latex foam. Latex foam is created by whipping air into the latex to create a soft foam pad. There are two processes used to make latex foam. These are the Talalay process and Dunlop process. Each creates a slightly different latex foam, with the Dunlop foam being heavier, firmer, and denser and the Talalay being lighter, softer, and more durable.

The main difference between the Dunlop and the Talalay foam manufacturing process is that the Talalay process includes an extra step during which the foam is flash-frozen, giving it an even consistency from top to bottom.

The Talalay latex foam manufacturing process is detailed below. The liquid rubber is whipped into a foam and poured into a mold filled with metal rods that protrude into the foam. A vacuum is placed on the mold, which removes air bubbles/pockets and distributes the liquid rubber evenly through the mold CO2 is run through the rods, flash-freezing the foamed rubber and locking in the consistency. Heat is sent through the rods, providing even temperature and yielding a consistent latex core without air pockets or uneven firmnesses. This special process, along with a specific blend of synthetic and natural latex, make a mattress that is soft and durable.


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