Solid Foam Mattress Manufacturers

As a China-based Sponge Mattress manufacturer and solid memory foam mattress supplier, Cixi Tiansheng Sponge Products Co., Ltd. builds polyurethane foam mattresses for bedding brands, furniture distributors, hotel projects and OEM/ODM programs. Our Sponge Mattress line uses a layered foam core: a high-density support base combined with a slow-rebound memory foam surface, finished with a cover chosen for the target market. Foaming, cutting, fabrication and vacuum compression are controlled inside our own production base, so density, hardness and final pack size stay under one roof.

What Our Sponge Mattress Range Covers

Our range covers solid foam mattresses and memory foam mattress constructions without coil springs. The core is produced from polyurethane foam, then cut, layered and bonded to the required profile. We adjust the recipe and layer arrangement to match firmness targets, order quantities and delivery routes.

• Layered core: 45D high-density support foam with slow-rebound memory foam surface.
• Vacuum compression to less than 30% of original volume; unpacking rebound in about one minute.
• Cover choices: teddy bear fleece, breathable corduroy, stain-resistant technical fabric with leather-like hand feel.
• Custom sizes, thicknesses, layer order and firmness for OEM/ODM programs.

Construction and Material Selection

The load-bearing character comes from the bottom layer. We specify 45D high-density support foam for its cohesion and fatigue resistance, so the mattress keeps its geometry under long-term weight and provides stable physiological support for the spine. The surface layer uses slow-rebound memory foam that responds to body temperature and pressure, conforms to body contours, distributes pressure, and relieves muscle tension.

Layer ratio can be changed for different markets: a thicker memory foam layer increases the pressure-relieving feel, while a thicker support layer increases overall firmness and durability. We confirm the final ratio with a pre-production sample before volume fabrication.

Application Fit

Sponge mattresses with this construction work well for residential sleep products, guest-room renovation programs, apartment fit-outs and contract bedding where freight cost and easy delivery are critical. The same vacuum-compression logic we use for Vacuum-Compressed Sponge Sofa products lets a complete mattress ship in a flat carton and be carried through narrow doors or small elevators.

• Residential and guest-room mattresses
• Hotel and serviced-apartment fit-outs
• Furniture brand OEM/ODM programs
• Export programs that need compact packaging

Vacuum Compression and Packaging

Vacuum compression is a key reason customers specify sponge mattresses for cross-border supply. A full-size mattress can be compressed to less than 30% of its original volume and packed in a standardized logistics box, reducing international shipping cost and simplifying last-mile delivery.

After unpacking, the foam rebounds to its full geometric shape within about one minute. For distributors, compressed mattresses also reduce warehouse space before sale.

Cover Options and Finish

Cover material affects comfort, appearance, breathability and cleanability. We match the cover to the mattress profile and verify the combination in the sample.

• Teddy bear fleece for a warm, soft sleeping surface.
• Breathable corduroy for a retro texture and airflow.
• Technical fabric with leather-like feel and stain-resistant surface for easier maintenance.

Quality Control and Testing

Quality starts at the raw material stage. We use polyurethane raw materials from BASF, Bayer and Dow, and our production lines use German KRACHT foaming pumps with Siemens PLC control. The closed-loop system manages raw material temperature, flow metering and foaming/molding processes for consistent batch quality.

Our testing center measures sponge ball rebound resilience, foam indentation hardness, tensile strength and density. The management system is ISO9001:2016 certified, and products have passed SGS and CE testing. For export orders, samples can be sent to a third-party laboratory for inspection before mass production.

Information We Use to Configure Your Solution

We prepare a configuration and quotation from concrete project data rather than a generic product sheet. The following inputs define the foam recipe, construction and packing method.

If your program also includes bedding accessories or seating, we can coordinate across our Memory Foam Pillow and Sponge Pet Bed ranges from the same factory quality system.

Frequently Asked Questions

• What is the difference between a sponge mattress and a memory foam mattress?In our product category, a sponge mattress means a fully foamed core without coil springs. A solid memory foam mattress uses a high-density support foam base with a slow-rebound memory foam top layer, which is the construction we recommend for pressure relief and long service life.
• How long does a vacuum-compressed mattress take to recover?Our compressed sponge mattress returns to its full geometric shape within about one minute after unpacking. Recovery can vary with room temperature, so we recommend unpacking in a normal indoor environment.
• Can we order a custom size or firmness?Yes. Our proposal starts from your size, thickness, target firmness, layer structure and cover choice. We produce pre-production samples so density and hand feel can be approved before volume fabrication.
• Do you support third-party inspection?We do. Samples can be sent directly to a third-party laboratory for testing. Our in-house testing center also documents density, hardness, rebound resilience and tensile strength for the relevant batch.
• Does vacuum compression affect foam performance?Vacuum compression reduces volume during transport only; it does not change the foam cell structure or support properties. The mattress returns to its original geometry after unpacking, and the support base continues to carry the load.