When it comes to mattresses, Saatva stands out from the crowd. Unlike most online mattresses that come compressed in a box, Saatva delivers high-quality mattresses that are built to last. With a commitment to superior craftsmanship and premium materials, Saatva has established a unique manufacturing network across the United States. In this article, we’ll take a behind-the-scenes look at how Saatva handcrafts their mattresses, ensuring exceptional quality and comfort for every customer.
Crafting with Premium Materials
Saatva prides itself on using only the finest materials in their mattresses. Each mattress is made with triple-tempered carbon steel coils, providing optimal support and durability. These coils are specifically designed to promote airflow, keeping the mattress cool and breathable throughout the night. Complementing the coil system is high-density, eco-friendly memory foam, offering pressure relief and contouring comfort. Saatva also incorporates organic cotton and natural latex into their mattresses, further enhancing their eco-conscious approach to sleep products.
Made-to-Order Manufacturing
Unlike mass-produced mattresses that sit in warehouses, Saatva takes a made-to-order approach. Every mattress is handcrafted in one of their 19 regional factories across the United States. This ensures that when you purchase a Saatva mattress, you receive a “factory fresh” product, manufactured specifically for you. By eliminating the need for long-term storage or compression, Saatva guarantees that each mattress is in its optimal state when it arrives at your doorstep.
The Saatva Manufacturing Process
Saatva combines traditional hand craftsmanship with modern materials and technologies to create their mattresses. Throughout the production process, each mattress undergoes meticulous scanning, enabling precise tracking of its progress on the factory floor. Let’s take a closer look at the manufacturing process for Saatva’s bestselling mattress, the Saatva Classic innerspring.
- Euro Pillow Top: The process begins with a 3-inch Euro pillow top. Saatva quilts a combination of fibers and comfort foams to a certified organic cotton cover, tailored to the specific comfort level—plush, luxury firm, or firm.
- Sewing and Flange Attachment: The quilted cover and side panels are then brought to the sewing department, where a fabric strip called a flange is sewn onto the edge of the panels. This flange will later be attached to the foam that encases the coil units inside the mattress.
- Coil System: Saatva Classic features a dual-coil system. The bottom coil layer comprises 13-gauge coils for exceptional durability. On top of this, a layer of individually-wrapped comfort coils, designed to respond to your body’s movements and minimize motion transfer, is added. This dual-coil system provides a responsive feel and promotes airflow for a cool and comfortable sleep experience.
- Special Features: The Saatva Classic incorporates two unique features. Firstly, the patented spinal zone active wire ensures enhanced back support and maximum pressure relief in the middle of the mattress where it’s needed the most. Secondly, a layer of CertiPUR-US-certified high-density memory foam offers additional pressure relief and comfort.
- Finishing Touches: Once all the panels are securely attached, an organic cotton border is added, followed by the application of Saatva’s signature gold damask binding using a tape edge machine. This meticulous process gives the mattress a polished and refined appearance, with attention to detail at every step.
Consistency and Quality Assurance
Regardless of the location where a Saatva mattress is produced, the same procedures and specifications are followed to maintain consistent quality. This dedication to craftsmanship ensures that every Saatva mattress delivers the same level of comfort and support, providing customers with a superior sleep experience.
Saatva’s commitment to handcrafting mattresses with premium materials and their made-to-order manufacturing approach set them apart in the industry. By combining traditional craftsmanship with modern techniques, Saatva ensures that each mattress is tailored to the customer’s needs and arrives in optimum condition. With their meticulous attention to detail and a focus on quality, Saatva continues to redefine what it means to provide a truly exceptional mattress for a restful night’s sleep.
