How our beds are made

How our beds are made
We have perfected our craft through experience over 160+ years. Craftsmanship is a tradition handed down from generation to generation. Using the finest materials ensures our beds can last for generations.

Our Mattresses

How mattresses are made details
"We know what's inside because we make each one"

Great mattresses start with the springs.

The starting point for comfort and support begins with the mattress core. Other manufacturers use foam blocks or off-the-shelf spring units for the core. We know better. That's why we design and manufacture spring units to insure long term comfort, proper support and sleeping pleasure.
  • Our Powercore™ Mattress Unit is a new, better spring system.
  • The individual spring design and placement, attachment, proper insulation between rows of coils and careful control of finished sizing make for a super durable and unusually comfortable spring unit.
  • The progressive support of our Powercore™ Mattress Unit senses individual body contours and provide targeted levels of support for the widest range of body types and sizes.
  • Coils feature more turns, more wire and more flexibility to provide better reaction and response to pressure points.
  • Tensile strength is 20% more than wire used by the leading U.S. mass manufacturer.
  • A straightened coil laid side by side to a conventional coil would be 20% to 100% longer.
  • More steel in a coil means more progressive support. More comfort.

Top quality padding and fabrics are the icing on the cake.

Our comfort padding options, soft, hypoallergenic covers and long wearing fabrics used to upholster each mattress provide the luxurious finishing touches that will welcome you home each night.
Talalay Latex Comfort Padding
  • Our Talalay latex is a pure, natural product from trees that is certified for authenticity and quality.
  • The Talalay process creates a more consistent padding material than latex using the Dunlop or other methods.
  • It is naturally cool, non-toxic, anti-bacterial and allergen resistant.
Nano Comfort Layers
  • Nano spring comfort layers consists of 1000's of tiny, individually pocketed springs, assembled into an integrated unit.
  • Talalay Latex and Nano springs combined make the softest, most luxurious, yet supportive mattress surface possible.
  • Unlike regular coils, Nano spring coils do not get progressively harder.
  • Nano springs are compliant, providing luxurious comfort with out the drawbacks of other natural or synthetic luxury filling materials: Like shifting, loose and compressed layers of padding.
  • Unlike horsehair, and other exotic filling materials in plush mattresses, Nano springs are hypo-allergenic.
Pulse Latex Comfort Padding
  • The benefits of natural latex feel and comfort at an attractive price.
  • Made using new Sonocore technology that uses 50% less energy to manufacture.
  • More consistent foam structure than traditional Dunlop latex for better ventilation, durability and comfort.
Memory Foam Comfort Padding
  • Originally developed in 1966 by NASA for astronauts and made famous by Tempurpedic®.
  • Responds to body's heat and gently cradles you, relieving pressure points and improving circulation.
  • Ours is Certi-Pur® certified Like Tempurpedic®, but we use only the highest quality.

Our commitment to making mattresses responsibly.

Since we actually make the mattresses we sell, our commitment to manufacturing responsibly is more than a promise.
  • Absolutely no solvents are used in the construction and assembly of our Powercore™ mattresses.
  • Steel for springs is mostly post-industrial recycled and is 100% recyclable.
  • Our Oekeo-Tex certified Natural Talalay Latex is CTC Gold Rated.
  • Our other padding materials and fabrics are CertiPUR-US and Oekeo-Tex certified.
More information at: (CTC) Cradle to Cradle Gold Certified™, Certi-Pur®, Okeo-Tex® and SonoCore Pulse Latex.
  • We use Fire Retardant designed and tested to meet CSPC standard 1633 without any use of chemical treatments.
  • Our foams are made without the use of PBDE, CFC's, mercury, lead or prohibited phthalates or other harmful substances.

Our Beds & Headboards

How beds are made details
"Built up to a standard, not down to a price." How beds are made logos

Beds & Headboards. Made by hand, one at a time.

Iron and Brass Beds & Headboards
  • Tubing is pure, heavy gauge brass or heavy wall thickness steel.
  • Decorative parts are individually cast, using carved wood patterns and sand molds
  • Forged iron components are solid iron bar, heated and hammered to shape by hand.
  • Details are precise and fully formed.
  • Solid metal to metal connections create an extremely rigid framework.
  • Components are hand finished in matched sets prior to assembly.
  • Painted finishes, applied by hand in layers have a soft, natural patina and are repairable.
  • Rail system, supporting the headboard, footboard and bedding, is carefully designed lifetime of service.
Wood Beds & Headboards
  • Responsibly sourced lumber is plantation grown mahogany and select hardwoods.
  • Components are fashioned from oversize lumber stock which we cut and kiln dry ourselves.
  • Veneers are carefully sliced and matched for grain and color.
  • Power tools are used for milling and cutting, components are finished by craftsmen using sharp hand tools.
  • Traditional methods of joinery allow for natural movement of wood with seasonal changes in temperature and humidity.
  • Surfaces are hand sanded. Finishes are applied in multiple layers then hand rubbed to a soft sheen.
  • Rail system, supporting the head/footboard and bedding, has an internal steel structure designed lifetime of service.
Upholstered Beds & Headboards
  • Finest top and full grain leathers and upholstery fabrics.
  • Framework is handcrafted from kiln dried hardwood.
  • Upholstery padding is built up in multiple layers to provide an appropriate level of firmness and comfort.
  • High resilience foam padding conforms to the required shape and returns to its full, original contour.
  • Tufting is done by hand in the traditional manner.
  • Great care is taken in the actual upholstering process to ensure a high quality fit.
  • Rail system, supporting the head/footboard and bedding, has an internal steel structure designed lifetime of service.
Our commitment to making beds responsibly.
Since we actually make the beds we sell, our commitment to manufacturing responsibly is more than a promise.
  • Steel and brass mostly post-industrial recycled and is 100% recyclable.
  • Hardwoods used in our beds are plantation grown
  • Adhesives and finishes are natural and/or non toxic water based (no harmful solvents).
  • Our finishes are repairable ensuring lasting beauty and longeveity

Over 7 generations of satisfied customers:

a59cheffy, AZ

Absolutely a beautiful piece of iron work! Pictures don't do it justice. Really pleased and look forward to sleeping in it for the rest of our lives! Shipped on a timely basis also!

Allison H, NY

Highly recommend this super comfortable mattress. At the end of everyday I am so thankful I have such a comfy bed. It is firm but not too firm, and the surface is such that you don't sink in so it is ...

oversixty, TX

My husband and I purchased the Estate 9000 Luxury Plush King Mattress w/ low profile foundation. We love the feel and comfort of the mattress. My husband has experienced hip pain with other mattresses...

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