Most online mattresses come stuffed in a box and won’t hold up for more than a handful of years. Saatva is different—we hand-deliver high-quality mattresses that are built to last. We’re able to do this because of our unique manufacturing network, honed over the 10 years we’ve been in business.
Since launching in 2010, Saatva has handcrafted every mattress in one of our 19 regional factories across the United States. All of our mattresses have always been made to order, right here in America.
When you purchase a Saatva, you get a “factory fresh,” American-made mattress that’s been manufactured for you. You’ll never get a mattress that’s been collecting dust in a warehouse or one that’s been folded and rolled up into a small shipping box.
We chatted with Stu Carlitz, who runs Saatva’s manufacturing network, to give you a glimpse into how our mattresses are made—and how he’s had to adapt the process during the ongoing coronavirus pandemic to ensure we’re able to meet safety standards without compromising quality.
How is a Saatva mattress made?
Saatva’s manufacturing process combines the best of old-fashioned hand craftsmanship with modern materials and technologies. As a mattress progresses to each stage along the factory floor, every step is scanned, so we know exactly where a mattress is at any point in the production process.
Here’s what that process looks like for our bestselling Saatva Classic innerspring mattress:
It starts with our 3-inch Euro pillow top. First, we quilt a combination of fibers and comfort foams to a certified organic cotton cover. (The combination is slightly different depending on the comfort level: Plush, Luxury Firm, or Firm.)
Then, the cover and quilted side panels are brought to the sewing department, where a strip of fabric called a flange is sewn onto the edge of the panels.
The flange is then attached to the foam that encases the two coil units inside the mattress. The bottom coil layer, or the support base, is made up of 13-gauge coils for maximum durability.
On top of this is a layer of more flexible, individually wrapped comfort coils that respond and contour to your body’s movements. They also help reduce motion transfer. The dual-coil system gives the mattress its responsive feel and promotes airflow for breathability.
The Saatva Classic has two more unique features: our patented spinal zone active wire and a layer of CertiPUR-US®1-certified high-density memory foam. These two features work together to provide enhanced back support and maximum pressure relief in the middle of the mattress, where you need it most.
After all of the panels are secured, an operator attaches an organic cotton border, and the whole thing is closed by a tape edge machine that adds our signature gold damask binding. The entire process is done by hand.
No matter where in the network a Saatva mattress is produced, it’s made using the same procedures and specifications, so the result is consistent every time.
We use only premium materials: triple-tempered carbon steel coils; high-density, eco-friendly memory foam; organic cotton; and natural latex. That’s why our products could never be compressed and rolled up into a box.
Choose the right mattress for you at Saatva
Saatva Classic Innerspring Mattress
Our flagship luxury mattress is expertly engineered with coil-on-coil construction for durability, a layer of memory foam for enhanced back support, and a cushiony Euro pillow top for extra comfort.
Choose the right mattress for you at Saatva
Contour5 Mattress
Luxurious body-hugging feel and pressure relief with 3” of ultra-premium, high-density 5-lb memory foam.
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Zenhaven Latex Mattress
Natural latex responds to every curve for pressure-free support and responsive comfort. Natural latex is supple, resilient, and durable, for the ultimate in elevated sleep. (It’s naturally hypoallergenic too.)
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Latex Hybrid Mattress
This hybrid mattress combines the pressure-free support of natural latex with the classic innerspring feel. Handcrafted with pure materials for the ultimate in cool and healthy sleep.
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Memory Foam Hybrid Mattress
This memory foam hybrid mattress features the perfect balance of body-contouring and responsive feel. Enjoy the innovative cooling system, which prevents overheating.
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Solaire Adjustable Firmness Mattress
Featuring precise 50 firmness settings on each side of the bed for personal customization. Natural latex and gel-infused memory foam layers provide luxurious comfort and support.
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Saatva HD Mattress
This luxury hybrid innerspring mattress is specifically engineered to support people weighing between 300 and 500 pounds. Plush upper layers made of foam and latex deliver comfort, while a high-durability coil base offers support.
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Saatva Rx Mattress
Specially designed to give maximum support and pressure relief that can help alleviate discomfort associated with serious and chronic back and joint conditions like sciatica, arthritis, herniated disc, and scoliosis.
FAQs
Does Saatva make their own mattresses?
Yes, we make our own mattresses. All of our mattresses are made to order in our US factories. No matter where a Saatva mattress is manufactured, it’s made using the same materials, procedures, and specifications, resulting in the same high quality for every order.
Find the best Saatva mattress for you
Saatva offers mattresses to suit every sleep style, from
America’s best-selling online luxury innerspring
to
The most luxurious memory foam with adaptive cooling & body-hugging support
to
Our dual-sided organic natural latex mattress for buoyant, pressure-relieving comfort
. All of our mattresses are made with high-quality materials and come with a 365-night home trial and lifetime warranty. Take our mattress quiz to find your perfect match.
- CertiPUR-US® is a registered trademark of the Alliance for Flexible Polyurethane Foam, Inc. ↩︎
