It will cost on average $980 to $3,920 to make a standard innerspring mattress. However, the exact amount will depend on certain important factors like the type of mattress, materials used, as well as the scale of production.
Keep in mind that this will encompass what you invest into purchasing materials such as foam, fabric, and springs, which will indeed take up around $150 to $400.
You would also want to take into account labor-related expenses, like cutting, sewing, and assembly, which will also cost around $100 to $200.
Do not overlook overhead expenses such as utilities, machinery maintenance, and administrative costs that will as well impact your overall costs.
Cost Breakdown to Make a Mattress
-
Foam ($30 to $180)
Foam remains one of the most important materials needed to make mattresses, especially when you consider the fact that they provide comfort and support.
However, it is imperative to point out that there are varying types of foam and the exact ones used will most often depend on the mattress design as well as the target market.
-
Polyurethane Foam
This is one of the most popular types of foam used in making mattresses because of its affordability as well as its versatility. This foam is known to coat around $0.50 to $1.50 per board foot.
Also, note that the quality will vary from basic low-density foam to higher-density foam known for its enhanced support and durability.
-
Memory Foam
This is another very popular option especially when you consider its body-contouring properties and pressure relief. However, it is necessary to point out that this foam is costlier especially when you consider many other types of foams. It is known to cost around $1 to $4 per board foot.
-
Latex Foam
This particular type of foam is made from natural or synthetic rubber. It is renowned for its foam high durability as well as the bouncy feel it offers.
It is also known to be expensive, falling within $3 to $6 per board foot. Also, note that natural latex foam is quite more costly than synthetic versions.
-
Fabric ($10 to $70)
This is another important material needed when making mattresses. It works to cover the exterior of the mattress as well as enhance both its aesthetic appeal as well as its durability.
-
Polyester/Cotton Blends
This is one of the most common as well as cost-effective fabrics, known to cost around $2 to $4 per yard. Keep in mind that they are durable and breathable, and this makes them highly sought after for budget and mid-range mattresses.
-
Knitted Fabrics
They are also quite popular especially when you consider the fact that they are softer, come with a more luxurious feel, and cost between $3 to $6 per yard.
-
Organic Cotton
This particular cotton is used to make eco-friendly and premium mattresses. This particular fabric is known to cost around $6 to $10 per yard, showcasing its higher production costs as well as environmental benefits.
-
Springs and Coils ($750 to $3,200)
They are very essential especially when making innerspring and hybrid mattresses, and they are known to provide support and resilience.
-
Bonnell Coils
Note that these conventional hourglass-shaped coils cost around $1.50 to $2.50 per coil. However, they are known for being quite durable while also providing top-grade support that makes them super ideal for lower to mid-range mattresses.
-
Pocketed Coils
Often referred to as encased or Marshall coils, it is used to describe individually wrapped in fabric sleeves, well renowned for offering better motion isolation and support. Keep in mind that they cost around $2.50 to $4 per coil.
-
Padding and Quilting ($20 to $100)
You can never overlook paddings and quilting when making mattresses as they boost the comfort of the mattresses and are important in the quilted layers of the mattress.
-
Fiberfill
This refers to synthetic material utilized in the padding of mattresses, costing $0.20 to $0.50 per ounce. It is renowned for the soft, cushioned feel it brings and that is why it is mostly used budget mattresses.
-
Wool
Note that this is a natural, breathable material that is most often used when making higher-end mattresses. It is known to cost around $5 to $10 per pound and has become very popular for its excellent temperature regulation and comfort.
-
Cotton Batting
This is also another natural material, and will cost between $1 to $2 per pound. It is very important especially when you consider its softness and breathability.
-
Adhesives and Binding Materials (10 to $30)
You will need these vital materials to hold the numerous layers of the mattress together.
-
Water-Based Adhesives
Quite popular for being eco-friendly adhesives, they cost around $5 to $10 per gallon. They are one of the most common especially due to their low VOC emissions.
-
Hot-Melt Adhesives
You would also want to consider these adhesives especially due to their strong bonds; however, note that they cost around $15 to $25 per gallon.
-
Edge Support ($10 to $40)
This is another important material that will add up to determine how much it costs to make a mattress. Keep in mind that they work to maintain the mattress’s shape as well as extend its durability.
-
Foam Rails
These are used around the perimeter of the mattress to ensure or guarantee edge support, although it will cost around $10 to $20 per set.
-
Reinforced Coils
They accord additional support at the edges, but will take up around $20 to $40 per set.