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.
