![]() The buns are cut down once again to make the piece of foam that is the right thickness, width, and height for a given mattress, he says. Those are cut down into smaller pieces, called “buns,” says Jamie Diamonstein, the chief product officer at mattress company Leesa. MDI plays a role in giving foams their “memory” and is often found in more expensive products, while TDI is generally used in cheaper foams, he says.Īfter the ingredients are mixed, and the foam has cooled (the reaction kicks off a lot of heat), manufacturers are left with massive blocks of foam. There are two types of isocyanates that have different chemical structures that may be used in foam, MDI (methylenediphenyl diisocyanate) and TDI (toluene diisocyanate), he says. “Essentially, the more isocyanate, the more firm that foam will be the less isocyanates, the foam will be,” Marino says. The firmness, in particular, is controlled by the ratio of isocyanates to polyols. Manufacturers can change the sensation of a foam by altering the proportions of different ingredients. To drastically oversimplify, foam is like “bricks of bubbles,” says JT Marino, co-founder of mattress-in-a-box company Tuft & Needle. Latex, which is less common in mattresses and has different components, can also be made into a foam. Mix them together in the right proportions and, voilà, you’ve got foam. Mattress foams are made with just three components: polyols, the basic building blocks, which are most often derived from oils, like petroleum isocyanates, which are reactants that trigger chemical changes when mixed with the polyols and blowing agents, which create gas bubbles in the foam. The Tuft & Needle Original mattress is entirely foam, but offers a great balance of firmness and support.įoam manufacturing shares some qualities with baking: You put together a handful of ingredients, mix them, and they go from a batter-like blend to the final product.
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