The Custom Manufacturing Process

Consultation & Specification: You provide the exact dimensions and desired feel (firm, medium, soft) to the

manufacturer.

Engineering: The manufacturer's engineers design the spring unit. They calculate the optimal spring count, layout,

 and wire tension to achieve the desired support and feel for the custom size.

Spring Coiling: High-carbon steel wire is coiled into individual springs of the specified height and number of turns.

Pocketing: Springs are fed into a machine that places them into sheets of fabric pockets, which are then heat-sealed

 or glued shut. This is done in rows.

Assembly: The rows of pocketed springs are assembled and glued together into a full-sized grid according to the

custom dimensions.

Zoning & Border Installation: If specified, springs of different gauges are placed in specific zones. The reinforced

border is added.

Compression & Rolling: The completed unit is compressed, rolled, and packaged for shipping. This is known as

a "roll-packed" unit, which is easier to transport and handle.