The conversation usually goes like this:

THEM: So, what’s your business?

ME: Springs

THEM: Springs?

ME: Yes, springs (I make a pinching gesture with my hand).

THEM: Oh, springs!

ME: Yes, springs.

THEM: So, what do you make springs for, like bed springs?

ME: (This is where I go into my elevator pitch) No, not bed springs, we are a custom spring manufacturer and make springs for OEM’s like (and I name several well-known companies).

So, I started thinking. How are bed springs made, or mattresses in general? Here’s what I found.


  1. Most mattress manufacturers subcontract the production of the innerspring unit to an outside firm that specializes in making springs. Once the completed spring unit is received and inspected, the workers manually apply the insulator. Next, they apply the cushioning layers that will determine the feel and comfort of the final product.
  2. While the mattress is being “built up” in one part of the plant, the decorative cover that will serve as the exterior for the top, bottom and sides is being made in another part. Usually this cover is made on a giant quilting machine, which controls a multitude of needles that stitch the cover to a layer of backing material. The stitching chosen serves both useful and ornamental purposes, as it must prevent the mattress cover from slipping or creeping over the layers of cushioning in addition to creating a visually pleasing exterior.
  3. Once the fabric is quilted, it is cut into panels that will fit the top and bottom of the mattress. The side panels are often cut from this same composite or made separately on a border machine. If side handles or vents are to be added, they are attached to the side panels before these are applied to the mattress.

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Maybe I should start talking to mattress manufacturers.

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Katy Spring & Mfg. Inc.