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"Foam factory" - any good?

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05 Jul 2012 06:58 - 12 Nov 2018 00:21 #1 by aoysgelt
While researching various memory foam mattresses I came across www.foamdistributing.com . They let you either buy individual foam sheets (I like that idea) or put them together for you to make mattress.

5lb foam used www.thefoamfactory.com/tech/5LBmemTech.html

Any thoughts?
Last edit: 12 Nov 2018 00:21 by Administrator TMU. Reason: Updating link to https: status

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05 Jul 2012 12:33 - 12 Nov 2018 00:23 #2 by Phoenix
Replied by Phoenix on topic "Foam factory" - any good?
Hi aoysgelt,

Foam Factory (AKA FBM or any of their other URL's such as Foambymail, mattressbymail, usafoam, foamdistributing etc) is not a business I would personally recommend or support.

Post #2 here talks about some of the reasons why and a forum search on FBM (you can just click this) will bring up more comments about them.

They are "cheap" ... and for some people this may be more important than knowing what they are actually buying ... and reason enough to buy from them.

Each person has a different risk tolerance of course but when it comes to what I sleep on ... I tend to take risks that are based on knowing what I am buying :)

Phoenix

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Last edit: 12 Nov 2018 00:23 by Administrator TMU. Reason: Updating link to https: status

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05 Jul 2012 13:08 #3 by aoysgelt
Replied by aoysgelt on topic "Foam factory" - any good?
Are there similar outlets - that just sell foams that I can pile together myself - but are more reputable?

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05 Jul 2012 17:39 - 12 Nov 2018 01:21 #4 by Phoenix
Replied by Phoenix on topic "Foam factory" - any good?
Hi aoysgelt,

Designing and building your own mattress can be a lot of fun but can also be quite frustrating and involves a lot more knowledge of how different materials, layers, and components interact than many people suspect. Posts 15 - 17 here may be worth reading and I would normally recommend working closely with a manufacturer who will be able to give good advice about all the different components (option 2 in the linked post) over using your own knowledge and separate sources to build your mattress (option 3 in the linked post) but for those who want to forge ahead with their own design anyway ... this will provide some options.

Ordering layers separately and where to order would depend on the material you wanted. Local mattress manufacturers and local foam shops can often be good quality and value sources if you want to see what you are buying first or talk to someone that has the skill and knowledge to help you make good choices.

NOTE: I would also be cautious about sizing because toppers can be cut to smaller sizes or have size variances that may be smaller than is listed on a website or than mattress components or bare layers that are meant to be used inside a mattress with "standard" mattress dimensions so if more exact sizing is important to you or you are ordering mattress components for inside a mattress instead of a topper then I would always confirm the actual dimensions of the layer, topper, or component you are ordering with the manufacturer or retailer you are ordering from.

FOR LATEX:

There are several good sources for latex toppers and/or full cores. My reference points are a few of the members of this site ...

www.diynaturalbedding.com/how-it-works/ 3" Dunlop & Wool toppers
www.flexuscomfort.com/ Talalay
latexmattressfactory.com/ Dunlop
www.mattresses.net/diylamaco.html Talalay and Dunlop (incl. slow response Dunlop)
www.matt-to-go.com/ Pure Talalay Bliss Talalay latex toppers
www.sleepez.com/ Talalay and Dunlop
sleeponlatex.com/ Dunlop
en.memoryfoamcomfort.ca/main.html Organic Dunlop (Canada)


These include a wide range of Talalay and Dunlop layers of several types and thicknesses and are all recommended members of this site which means that I believe they have among the best quality and value in the country. Some other good sources include ...

www.kttenterprises.com/index.html . Any size, thickness, or ILD for Talalay Global Talalay and well priced per board foot.
www.sleeplikeabear.com/ Has any size and thickness and ILD of Talalay latex made by Talalay Global.
www.foamorder.com/ Also sells Talalay and Dunlop and their Dunlop can be ordered in 6" cores in a variety of 5 firmness levels. Also, check their clearance items.
Mattressess247 here Blended Talalay and 100% natural Dunlop (including zoned Dunlop cores) with ebay stores.ebay.com/mattresses247
www.ebay.com/usr/latextoppers Sells latex cores and toppers including organic Dunlop from Latexco that are accurately listed.
stores.ebay.com/organicandmore/ Natural and organic Dunlop.
lakemattressandfurniture.com/bedding/toppers/ Dunlop
www.organicmattressshop.com/latex-toppers.html Convoluted latex topper.

Google searches on ebay, amazon, and other similar sites and sometimes in the big box stores can sometimes bring up more alternatives and sometimes lower prices but again it's important (to me at least) to know that what you order is what you get and that the vendor has a good reputation and integrity. In some cases, you will find comfort exchanges or seconds on these sites (sometimes identified and sometimes not) and sometimes the products will be either poorly described or mis-described completely. If you are OK with this and you trust the vendor (or they have a great refund policy) then they can be a good source as well.

FOR SHREDDED LATEX TOPPERS:

Shredded latex toppers can "displace" more than solid latex layers and provide pressure relief with less risk to alignment. Some sources for different versions of these I'm aware of include ...

www.cozypure.com/mattress-pads-toppers/l...x-topper-best-seller see this post for more detailed information and feedback

www.flobeds.com/products/linens/mattress-toppers.htm (has a zipper so the shredded latex can be added, removed, or zoned in different areas. See this post for more detailed information and feedback).

FOR POLYFOAM:

Again local foam shops are usually a good source for a wide range of polyfoam in terms of both information, quality, and firmness but online there are also several good options that will accurately describe their foams and their qualities and have good prices. A few of these include (pricing hasn't been compared) ...

Prices online:

a1foamandfabrics.com/site/index.cfm
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www.albanyfoam.com/
www.foamonline.com/ (they also sell Talalay latex but be very careful that you receive the correct ILD)
www.foamorder.com/
www.foamproducts.net/

Phone for prices:

www.bobsfoam.com/
www.foam-futon.com/
houseoffoam.net/
www.newenglandfoam.com/ (min order $200 last time I talked with them)
www.perfectfit.com/

Some of these may also sell other types of foam including memory foam, gel memory foam, or latex and many don't compress their foam for shipping and will only ship foam layers that are either thin or small enough to fit the UPS size restrictions so phone first to check if they can ship the size and thickness you are looking for.

FOR MEMORY FOAM:

There are so many different types, qualities, and properties of the many types of memory foam that knowing what you are buying depends on the knowledge and description of the merchant you are buying from. It is also often the most mislabeled type of foam and low density or uncertified memory foam is being sold everywhere with descriptions that are misleading or in some cases completely wrong. They are also more widely available because they are a common topper material and only used in comfort layers and never used as part of the support system of a mattress.

Some (of the many) better sources of memory foam layers that carry more than one type of memory foam are in post #12 here and includes ...

en.memoryfoamcomfort.ca/main.html (A recommended member of this site ... Canada)
www.foamorder.com/
http://lakemattressandfurniture.com/bedding/toppers/


Some other links to online outlets that are not foam suppliers and may have little knowledge of the quality or specifics of the memory foam they sell but do sell memory foam toppers are in this topic .

FOR GEL FOAMS:

You can read more about the different types of gel foams in post #2 here . The majority of the gel memory foam toppers available on the internet are the type that uses gel beads or particles in the memory foam.

www.sleepwarehouse.com/ Gel memory foam
www.lakemattress.biz/Toppers.html Gel memory foam
Gel memory foam (3 lb only)
Solid gel on top of either HR polyfoam, memory foam, or latex
www.sleepart.com/ Solid gel on top of either memory foam, polyfoam, HR polyfoam or latex
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FOR BUCKLING COLUMN GEL

ADMIN NOTE:Removed 404 page link | Archived Footprint: intellibed.com/store/products/mattress-topper/ Intelligel

FOR WOOL TOPPERS:

Post #3 here has some of the better sources and more information about wool toppers for those who want to add a wool topper as a layer of their mattress. All of these are knowledgeable and informative about their products on the phone.

FOR MICROCOIL TOPPERS:

microcoil with a quilted organic cotton cover
ADMIN NOTE:Retired Website | Archived Footprint: groovygreenorganics.com/3-organic-mattress-topper
www.ikea.com/us/en/catalog/products/80298172/ microcoil with a 1.25" 1.5 lb polyfoam layer on top of the microcoil.
www.therapedic.com/bedding-and-home/matt...oil-mattress-topper/ Microcoil/memory foam topper.
www.naturepedic.com/our-products/pads-to...essentials-pillowtop Microcoil topper.
www.berkeleyergo.com/posturflo-pad/ MicroCoil/Latex topper.

FOR INNERSPRINGS:

www.mattresses.net/copocobylean.html This is a high quality zoned pocket coil with firmer rows of coils to provide edge support. They are also a member of this site.

Both of the following innerspring manufacturers have also told me that they would ship an individual spring unit for those who are willing to pay the shipping (which can be costly).

www.texaspocketsprings.com/contact.htm Prepay with cheque or possibly Paypal.

www.hsmsolutions.com/ (Hickory Springs)

FOR MATTRESS or TOPPER COVERS:

Mattress covers can be one of the most significant parts of the cost of a mattress and also one of the most important. Not only can they have a major influence on how a mattress looks and performs ... cheap or thin mattress covers will not properly protect the foam inside and in particular with latex will allow the foam to degrade and break down much more quickly and significantly lower its longevity. Some of the better sources of zip mattress covers include ...

www.sleepez.com/mattresscomponents.htm (a member of this site)
www.mattresses.net/ (a member of this site)
sleeponlatex.com/products/organic-cotton-cover-1 (a member of this site)
latexmattressfactory.com/ (a member of this site)
en.memoryfoamcomfort.ca/main.html (a member of this site ... Canada)
sleeplikeabear.com/mattress_cover (good selection)
ADMIN NOTE:Removed 404 page link | Archived Footprint: sleeplikeabear.com/mattress_cover
www.diynaturalbedding.com/product-category/ticking/ (including an "expandable" organic cotton knit ticking)
www.foamorder.com/mattress-cover.html (several covers including quilted latex)
mattresses247.com/ or stores.ebay.com/mattresses247/ (knit and quilted)
www.purerest.com/ (not listed so a phone call and quote is needed)
mattresscover.com/ (has access to covers that are not listed on the site so a phone call may be necessary)
www.supremequilting.com/mattress-covers-c1 In Canada.

OTHER SUPPLIES or DIY PILLOW SUPPLIES:

www.cozypure.com/miscellania/diy-materials-and-fabrics Wool batting, cotton fabrics, cotton batting, lanoodles latex.
www.diynaturalbedding.com/product-category/supplies/ Wool batting, wooly bolas, cotton fabrics, inner and outer pillow cases, kapok, millet hulls, shredded latex.
whitelotushome.com/all-products/wholesale-fibers/ Wool batting, cotton batting, buckwheat hulls, kapok
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www.foamorder.com/accessories.html Shredded foam/memory foam, down/feathers, polyester pillow stuffing, dacron wrap, pillow fabrics/ticking.
openyoureyesbedding.com/ Buckwheat hulls, millet hulls, pillow cover.
www.ecochoices.com/ecobedroom/bedding/pillowprotectors.html cotton/wool cover.
www.beanproducts.com/mm5/merchant.mvc?Sc...&Product_Code=7ZFFOL Shredded latex.

Most upholstery stores or foam suppliers will carry upholstery glue that can be used to glue foam together but you can find it here and here and here as well.
ADMIN NOTE:Removed 404 page link | Archived Footprint: sleeplikeabear.com/product/MISC-LTXGLUE-EQ

Some additional sources for zip pillow covers are in post #8 here .

Of course, these are not a complete listing and google searches specific to the material or component you are looking for will bring up more sources but it should be enough to provide good quality sources for most of the materials or components that are needed.

Bedtimes magazine also has a list of suppliers for different types of mattress components in their supplies guide here for those who are looking for other types of materials or components that may be harder to find at a consumer purchase level but many if not most of these may be wholesale only and may require some research and phone calls to find out if any of them would sell in small amounts to consumers.

Phoenix

Researching for a mattress?... Be sure to read The Mattress Shopping Tutorial.
Click here for TMU Discount Codes if purchasing from Our Trusted Members.
For any mattress questions Ask An Expert on our forum
Last edit: 12 Nov 2018 01:21 by Administrator TMU. Reason: Removed Page Not Found Link (404 Error) and Updating link to https: status

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16 Dec 2012 21:31 #5 by jp2600
Replied by jp2600 on topic "Foam factory" - any good?

Phoenix wrote: Hi aoysgelt,

Designing and building your own mattress can be a lot of fun but can also be quite frustrating and involves a lot more knowledge of how different materials, layers, and components interact than many people suspect.......(snipped for size)

Phoenix


Phoenix - Thanks for all this great information! I have been lurking for a little more than a week and have learned a ton. Now, the million dollar follow-up question, to your great post: Where can I purchase a Lura-Flex 660 Foam Encased spring unit by itself? Or something similar. I am doing a complete DIY innerspring and that seems to be the hardest part to get a hold of.

I bet it's a long shot, but thought I would pose the question. Thanks again for all this great info!

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16 Dec 2012 22:36 - 12 Nov 2018 01:25 #6 by Phoenix
Replied by Phoenix on topic "Foam factory" - any good?
Hi jd2t00,

Unfortunately, I don't know of a source that sells innersprings by themselves to consumers.

You would also need to buy a good insulator and preferably a flex net as well to prevent the foam from sinking in to the coils and this should be stretched over the edges and stapled into the foam surround to prevent it from shifting. Even better from a durability point of view would be a spring that was re-inforced on the edges without the foam surround. There are a couple of videos here and here that would be worth watching to see the whole construction of an innerspring mattress with and without a foam surround.
ADMIN NOTE:Removed 404 page link | Archived Footprint: youtube.com/watch?v=hy4feiPdZiU


Bay Bed and Mattress is one of the members here that builds component innerspring latex mattresses that offers a layer or component choices and exchanges and ships across the country but they are pocket coils rather than a luraflex.

Another option would be to talk with one of the many manufacturers that makes a 660 luraflex mattress and see if you could sweet talk them into selling you just the innerspring/insulator assembly or better yet you may be able to have them build you the mattress you want at a lower cost than buying the components separately.

Another option would be to go to a liquidator and buy a cheap mattress that used the coils you wanted and then remove the cover and the foam.

If you do have success with an innerspring purchase it would be great to let us know where you got it from :)

Phoenix

Researching for a mattress?... Be sure to read The Mattress Shopping Tutorial.
Click here for TMU Discount Codes if purchasing from Our Trusted Members.
For any mattress questions Ask An Expert on our forum
Last edit: 12 Nov 2018 01:25 by Administrator TMU. Reason: Removed Page Not Found Link (404 Error)

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16 Dec 2012 23:05 - 12 Nov 2018 01:28 #7 by jp2600
Replied by jp2600 on topic "Foam factory" - any good?

Phoenix wrote: Hi jd2t00,

Unfortunately, I don't know of a source that sells innersprings by themselves to consumers.

You would also need to buy a good insulator and preferable a flex net as well to prevent the foam from sinking in to the coils and this should be stretched over the edges and stapled into the foam surround to prevent it from shifting. Even better from a durability point of view would be a spring that was re-inforced on the edges without the foam surround. There are a couple of videos here and here that would be worth watching to see the whole construction of an innerspring mattress with and without a foam surround.
ADMIN NOTE:Removed 404 page link | Archived Footprint: youtube.com/watch?v=hy4feiPdZiU

Bay Bed and Mattress is one of the members here that builds component innerspring latex mattresses that offers a layer or component choices and exchanges and ships across the country but they are pocket coils rather than a luraflex.

Another option would be to talk with one of the many manufacturers that makes a 660 luraflex mattress and see if you could sweet talk them into selling you just the innerspring/insulator assembly or better yet you may be able to have them build you the mattress you want at a lower cost than buying the components separately.

Another option would be to go to a liquidator and buy a cheap mattress that used the coils you wanted and then remove the cover and the foam.

If you do have success with an innerspring purchase it would be great to let us know where you got it from :)

Phoenix


Thanks for the tips! If I find something I will certainly update the thread.
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17 Dec 2012 15:35 #8 by jp2600
Replied by jp2600 on topic "Foam factory" - any good?
Just as an update for anyone wanting to go the DIY route, or perform mattress surgery, I have found the following site useful: bedtimessuppliesguide.com/

It lists suppliers of every mattress component you could think of. You have to do some due diligence, as to the product quality and if they sell to the public, but it is a really good resource for finding components.

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19 Apr 2017 13:34 #9 by atopic
Replied by atopic on topic "Foam factory" - any good?
I am a newcomer to The Mattress Underground. I stumbled upon this thread, because I am in the market for a 6"-thick piece of polyfoam to use as a base for a 3" TempurPedic mattress topper. My goal is to build a mattress that replicates (as closely as possible) the feel of our original TempurPedic purchased back in 1997.

I wonder if you could help me evaluate my options. Thanks to your very helpful comments, I have narrowed down my foam choices to two suppliers at this point: Foam Online and Foam Order. The spec's (as shown on their websites) for each of the foams I'm considering are as follows:

(1) Foamonline.com - "High Resilience Foam". Density = 3.0 lbs; ILD = 34. NOTE: these numbers differ slightly from the data shown elsewhere on their website under "Descriptions of Foam Types." There the spec's for High Resilience Foam are: weight = 3.0 lb/cu.ft.; density = minimum 2.50 lbs/cu.ft.; ILD = 35% max. Price for queen-size foam: $504.10.

(2) Foamorder.com - "EverFlex V34" Conventional Foam, high resilience. Density = 2.6 lbs/cu.ft.; ILD = 34. Price for queen-size: $490.00.

The only other thing I have to go on are some BBB reviews for each company. Both had a few complaints logged against them, and I'm inclined to be a little more concerned about the claims against Foam Online, aka Upholstery Decor, Inc. I'm also not sure what to make of the discrepancy between the specifications listed in different places on the Foam Online website.

Do you have any thoughts? Any other suggestions for me?

Thanks for providing such a great resource in this very confusing world of mattress buying!

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19 Apr 2017 18:18 - 12 Nov 2018 01:29 #10 by Phoenix
Replied by Phoenix on topic "Foam factory" - any good?
Hi atopic,

Welcome to the Mattress Forum! :)

I have narrowed down my foam choices to two suppliers at this point:


The information I found at foamonline.com in the description section correctly describes high Resilience (HR) foam – a density over 2.5 lb and a support factor of at least 2.4. In their ILD chart, they show that they offer their HR foam in ILDs of 15, 20, 30, 40, 50, and 70. This would all seem to be proper HR foam.

The information on the foamorder.com site lists the EverFlex V34 at 2.6 lb density with an ILD of 34, but they don’t list the support factor. I would phone to make sure it is 2.4 or above, as many foams as mistakenly referred to as HR when they in fact are only above 2.5 lb in density but they have a support factor lower than 2.4.

Regarding High Resiliency polyfoam (HR):
This is the highest grade of polyfoam and weighs 2.5 lbs per cubic foot or more. To qualify as HR it must also have a support factor of 2.4 or higher. This support factor is an important part of why a HR polyfoam has the qualities it does as it is made with a different chemical formula and has a different cell structure than the two lower grades. I would also encourage you to read the section on polyfoam as a support core section as HR polyfoam is one of the most mislabeled materials in a mattress ... both in stores and on the internet. Because of its different formulation, it is more durable in all ILD's from very soft to very firm and is suitable for use in any layer of a mattress including comfort layers. It is more expensive than the lower grades though so you rarely see soft HR foam in the comfort layers of a mattress except in those made by smaller local and regional manufacturers as it does not have the same profit margin as the lower grades that are sold with a "story" attached. Some of the best HR foams come close to latex and are good quality, have good resilience, and will last for many years.

The only other thing I have to go on are some BBB reviews for each company. Both had a few complaints logged against them, and I'm inclined to be a little more concerned about the claims against Foam Online, aka Upholstery Decor, Inc.


I am not a big fan of the BBB for many reasons and you can see my thoughts about the BBB in post #3 and #4 here and points #1 and #5 in the comments here from another member and in post #4 here .

I'm also not sure what to make of the discrepancy between the specifications listed in different places on the Foam Online website.


I didn't find any discrepancies regarding their HR foam on their site, but I may have missed something.

I hope that helps.

Phoenix

Researching for a mattress?... Be sure to read The Mattress Shopping Tutorial.
Click here for TMU Discount Codes if purchasing from Our Trusted Members.
For any mattress questions Ask An Expert on our forum
Last edit: 12 Nov 2018 01:29 by Administrator TMU. Reason: Updating link to https: status

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