What's the Best Mattress | We're going with Sleep EZ(I think), but I've got a few more questions

Re: We're going with Sleep EZ(I think), but I've got a few more questions

Reply #2 Mar 15, 2012 4:32 PM

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GKDesigns

Joined: Mar 15, 2012
Points: 182

My DIY Latex Mattress Notes

Contents

Objective
Latex ⇒ Process ⇒ Latex Foam Rubber
Firmness: ILD Scales and Reference Builds
Elements of the DIY Latex Mattress
My DIY Latex Mattress, Platform, and Pillow
Related Links

Objective

To build a custom 100% Latex foam rubber mattress that:

Contains no hazardous materials;
Provides good pressure relief and neutral spinal alignment for my sleeping profile;
Maintains a comfortable bedding temperature and humidy climate;
Is easily maintained by replacing simple, layered components (no more mattress shopping).

Latex ⇒ Process ⇒ Latex Foam Rubber

Latex - any of several natural and/or synthetic colloidal polymers suspended in an aqueous solution. Basically, rubber particles in water. [LI]

100% Latex - generally means no non-Latex materials are included i.e. a 100% Latex mattress should not contain any petrochemical-based polyurethane foam (polyfoam), visco-elastic foam (memory foam), steel coils/innersprings, or other non-Latex materials except a stretchy cover.

100% Natural/ALL Natural/Organic Latex - natural rubber (NR) Latex that is harvested sustainably by tapping Hevea brasiliensis rubber trees grown in tropical climates. Organic generally means that the natural rubber Latex is produced by organic farming methods. Also read about biorubber produced from the Guayule plant grown in the US desert southwest.

Variations in grow conditions cause variations in harvested Latex quality and market price.
Molecular inconsistencies make 100% natural Latex foam rubber less consistent and durable (~10 year warranty).
100% natural Latex formulation offers less precise control over the density/firmness range (17-38 ILD) of Latex foam rubber.
100% natural Latex foam rubber is said to be a bit springier/bouncier/more elastic, compresses firmer faster (more supportive), and is not as resilient as synthetic/blended Latex foam rubber (less durable).
100% natural Latex foam rubber is said to soften with age, decreasing support.

Synthetic Latex - Styrene-Butadiene rubber (SBR) Latex that is a man-made molecular equivalent of natural rubber Latex developed during WWII when natural rubber Latex sources became scarce.

Molecular uniformity makes synthetic Latex foam rubber more consistent and durable.
Not as elastic and contouring as 100% natural Latex foam rubber.
Synthetic Latex foam rubber is said to stiffen with age, increasing support.

Blended Latex - a manufacturing process specific blend of natural and synthetic Latex (for example, 35/65 for the Dunlop process; 30/70 for the Talalay process). Latex is blended to optimize the desired attributes of Latex foam rubber for a given manufacturing process and product, and to stabilize the market price of Latex. Blended Latex is said to be used in the majority of bedding products that use Latex foam rubber.

Some blended Latex product is labeled "Natural" (vs. "All Natural") to greenwash it. Unfortunately, this marketing finesse confuses and undermines the natural credibility of blended Latex.
Synthetic Latex makes blended Latex foam rubber more consistent and durable (~20 year warranty).
Synthetic Latex makes blended Latex foam rubber more economical since it uses less natural Latex.
Blended Latex formulation offers more precise control over the density/firmness range (14-50 ILD) of Latex foam rubber.
Blended Latex foam rubber is said to stiffen with age, increasing support.

Dunlop Process - the original/standard manufacturing process for producing Latex foam rubber developed in 1929. It is most common and has been improved upon. Uses 100% natural or blended Latex.

~US market product share: 80% Dunlop (15% using 100% natural Latex; 85% using blended Latex).
A less expensive process that produces a snowflake cell structure and a foam rubber that is denser/heavier, less airy, less consistent resilience and firmness throughout, that can be more dense toward the bottom of the mold due to particle settling (flipping a core may change its surface firmness; cutting a core into thinner layers may not yield layers of equal firmness; compresses firmer faster than Talalay, making it more supportive and perhaps more suitable for use in the support core layer for heavier sleepers).
It is said that very soft (<22 ILD) Dunlop foam rubber does not last, perhaps making it less suitable for use in the comfort layer.
The less expensive Dunlop process makes using 100% natural Latex more economical.

Talalay Process - a more sophisticated and expensive process for producing Latex foam rubber developed during WWII. Only a few manufacturers worldwide use the Talalay process. Uses 100% natural or blended Latex, but Talalay with 100% natural Latex is said to be most difficult to process since it lacks the more precise formulation and strengthening characteristics of synthetic Latex.

~US market product share: 20% Talalay (2% using 100% natural Latex; 98% using blended Latex).
A more expensive process that produces a Latex-efficient, rounder foam cell structure and a foam rubber that is less dense/less heavy, more airy, more consistent resilience and firmness throughout, top-to-bottom (compresses firmer slower than Dunlop). The process allows for more consistent control over and a wider range of firmness.
Talalay Latex foam rubber is extensively washed to remove catalyst chemicals and residual soaps and proteins, the leading cause of premature softening.
Given the few manufacturers, the ILD grading of Talalay Latex foam rubber firmness, particularly for blended Latex, is said to be most accurate/reliable.
Talalay Latex foam rubber is more breathable than Dunlop Latex foam rubber.

Talalay Latex foam rubber is preferred for the comfort layer of a mattress:
Consistent and incremental firmness grading; reliable.
Wider firmness range; softer.
Compresses firmer slower; better cradling/gap support.
Consistent cell structure and density/resilience; resists body impression.
More breathable; better ventilation.

Latex Foam Rubber - a supple rubber (not foam) produced by vulcanizing Latex using the Dunlop process or the Talalay process plus small amounts of other necessary and proprietary ingredients.

WARNING: Latex foam rubber can be flammable. Keep it away from sources of combustion. It may be advisable to not put a DIY Latex mattress in a careless environment/bedroom.
A unit of Latex foam rubber that comes out of its manufacturing process mold is called a core (or block), which is not conceptually the same as the support core layer of a mattress. A mold core is cut into layers for use in bedding applications such as in the comfort layer and in the support core layer of a mattress. It seems that some layers are cut to 1", 2", and 3" thickness (from 6" cores); while some layers are cut to slightly less than 1", 2", and 3" thickness (from 5.6" cores), so confirm exactly what you are buying.
ILD grading of firmness is the amount of force or weight it takes to compress an area of foam material to a percentage of its uncompressed thickness. The defined ILD test area and percentage compression may not be equivalent across various manufacturers, materials, and products. Also, different materials can have similar ILD grading but different compression-firmess curves; one material may compress firmer faster than the other, offering firmer support (a higher compression-firmness curve). So, beware comparing apples to oranges.
Latex International Talalay blended Latex foam rubber core firmness is tested in 9 places and graded on an ILD scale ranging from less than 14 ILD super soft to greater than 44 ILD super firm. These test ILDs, the nominal ILD, and the density lbs may be listed on the product label, but this information/label can go missing during fabrication and handling.
A 3" layer will behave firmer than two 1.5" layers cut from the same 3" layer.
Latex International Talalay 100% natural and blended Latex products are OEKO-TEX Class 100 certified, the healthiest classification, and are considered completely safe for bedding applications. Properly processed Latex foam rubber does not off-gas like petrochemical-based polyfoam, memory foam, and chemically treated materials. It initially smells slightly vanilla sweet or rubbery but this quickly dissipates.
(Polyfoam and memory foam may contain up to 7 toxic chemicals: Tetrachoroethane, acetone, dimethylformamide, Methyl benzene, Methylene dianiline, toluene-neoprene, and Vinilideine chloride; 1 non-toxic chemical: diphenyl diisocyanate; and 1 natural material: water. Good quality HR grade polyfoam density is 2.5lbs./cu.ft. or higher. Good quality memory foam density is 5lbs./cu. ft. or higher.
100% natural Latex has 6 non-toxic chemicals: acrylate resins, diphenyl diisocyanate, Phenol-melamine resins, Phenol-urea, Polyvinyl acetate and waxes styrene- butadiene copolymer; and 3 natural materials: fats, hevea brasiliensis milk, and water.
Synthetic Latex has 5 non-toxic chemicals: 2-chloro-1–3-butadiene, diphenyl diisocyanate, metallic oxides, Phenol-melamine resins, sulfur, Tellerium; and 1 natural material: water.) [LI]
Latex foam rubber graded below 19 ILD is considerably soft and said to wear/breakdown sooner; even more so for 100% natural Latex; even more so for high wear application in the comfort layer of a mattress.
Denser/Firmer Latex foam rubber lasts longer, so Dunlop may last longer than Talalay, and firmer may last longer than softer. However, all Latex foam rubber requires careful handling since firmer can break/crack apart (like cake) and softer can tear/pull apart.
Latex foam rubber is more breathable than other foams (polyfoam and memory foam).
Poorly formulated/processed and/or uncovered/exposed Latex foam rubber is subject to oxidation, sunlight/UV degradation, and premature aging (dries, cracks, and crumbles apart).
Environmentally friendly, naturally derived, biodegradable, clean and toxin-free.

Bedding Attributes
Feels luxurious/supple; consistent feeling surface compression.
Initially smells faintly pleasant, if at all.
Bouyant, uplifting, bottomless, springy, bouncy, lively, fun.
Instant sleeping profile shape conforming/contouring; very good point elasticity.
Instant resilience/recovery (freedom of movement); resists body impression (no mattress flipping or rotating required).
Dampens motion transfer (not completely but well enough).
Wide range of thickness/softness for comfort and thickness/firmness/progressive firmness for support... soft and supportive... making it suitable for use in both the comfort layer and the support core layer of a mattress.
A single firmness of Latex foam rubber is not sufficient for comfort and support. Multiple layers of increasing/progressive firmness must be stacked in layers that stay put by their own weight and friction.
Naturally breathable... has an open-cell structure that air flows through and an edge-to-edge array of process mold pincore holes that allow air to move up/down through the core. So as you move about and by natural convection, a Latex foam rubber core naturally breathes and ventilates. This ventilation is aided by placing wool between your body and the Latex foam rubber, and by placing the mattress on a platform that ventilates freely from below. Beware a less than 100% Latex mattress that includes other materials that compromise this ventilation and insulate body heat and moisture.
Said to be 3x more durable than polyfoam; resists comfort layer breakdown and outlasts support layer coils/innersprings.
Toxin-free, hypoallergenic, dust mite resistant, anti-microbial, mold-proof, and mildew-proof.
No chemical fire retardants/dust.

Handling Tips
It is easier to handle, vacuum pack, and ship 3" layers vs. a full 6" core. (Note that 3" layers give the kit Latex mattress customer something to do, but shuffling 3" layers up and down does not necessarily fix mattress comfort or support. Meanwhile, the comfort exchange warranty period expires and the seller enjoys less returns at the customer's expense and discomfort. Same marketing applies to excessively zoned Latex... too many zones give the customer many pieces to move around, but not because all the right zones are there and you just have to solve the zoning puzzle.)
Handle layers gently to avoid breaks and tears.
Fold a layer in thirds and wrap/flip it in a fitted sheet to pick it up/move it more easily.
Place layers on clean sheets to keep them from collecting dust/hair.
Push/Jiggle (don't pull) the edge of a layer to walk/wave it into position.
A firmer ILD layer is more likely to break/crack when severely folded and loaded.
Exposure to air/ozone can oxidize/prematurely age Latex foam rubber. Keep it covered.
Sunlight can degrade/prematurely age Latex foam rubber. Keep it out of the sun.

Fabrication Tips
To cut Latex foam rubber, use a sharp electric knife such as the Hamilton Beach Classic Chrome Electric Knife with opposing blade cutting action.
Place the Latex foam rubber layer on a flat sheet on a smooth floor and give it a few jiggles to settle it to its relaxed dimensions. Softer Latex (19 ILD) is more likely to stretch and distort.
Confirm the layer dimensions and that the pincore hole pattern is not distorted so that it can be used for layout.
Choose the best edge/end of the layer to include in the layout.
Measure nominally from the end reference edge or from both side reference edges to mark the layout. Round up to the nearest pincore line of holes to cut through the holes. Cutting through the pincore holes saves marking actual cut lines and saves cutting through solid Latex. Count holes when necessary to confirm the layout symmetry. Note that the holes I worked with were ~0.75" apart.
Aside from rounding up to the nearest pincore line of holes, keep the layout dimensionally accurate so that the Latex fits together without excessive compression. Note that adding just ~1" of extra length to a 19 ILD comfort piece is sufficient to ensure that the piece fits snugly into the mattress cover.
Place a length of thin material under the cut line to protect the sheet/floor from the knife blade. Place a 1x8 on each side of the cut line to raise the Latex evenly a bit. Raising the Latex ensures that long cuts are clean through on the first pass and saves banging the end of the knife blade and mechanism.
Kneel out onto the Latex, avoid distorting the cut line, and cut the Latex with an electric knife. It should cut cleanly and easily and quickly enough. Poke the knife blade vertically into a pincore hole to begin a corner cut.
To seam/bond/repair Latex foam rubber, use 3M™ Foam Fast 74 Spray Adhesive Clear (amazon.com). Mask the sides of the joint with 2" blue painters tape to catch any over spray, spray both surfaces, wait a minute until tacky, then carefully align and close the joint evenly since the surfaces will bond instantly as they make contact. Clean the spray tip in mineral spirits.

Wool - a natural, renewable, animal fiber with unique properties for application in the comfort layer of a mattress (and in clothing).

Absorbs up to 30% of it own weight in water without feeling wet, keeping the humidity surrounding you at a low and steady level.
Insulates in both winter and summer conditions. Wool's hydrophilic ability to wick away moisture that would otherwise collect and evaporate near your body, aids body temperature regulation, keeping you warm and dry in cool weather, and cool and dry in warm weather. When water evaporates, it consumes heat energy. Wool helps to regulate this evaporation process to keep you feeling more comfortable.
Naturally resilient fibers with a springy spiral crimp that withstands bending and compression 200 times better than synthetic fibers (polyester).
Naturally flame retardant; difficult to ignite and extinguishes itself when the flame source is removed.
Breathable, durable, resists compression/breakdown.
A good ventilation medium between you and Latex foam rubber.

Firmness: ILD Scales and Reference Builds

Density, firmness (surface firmness, 'hand', 25% IFD or ILD), and compression modulus (support factor, modulus, sag factor, sac factor, 65% ILD/25% ILD) are discussed here. ILD and IFD are the same test method, but a Latex foam rubber test sample is said to be 6" thick and a polyfoam test sample is said to be 4" thick; so the deflection distance and load/force rating are not equivalent/comparable (32 ILD or IFD polyfoam will be firmer than 32 ILD or IFD Latex foam rubber by roughly 20%).

The following ILD scales and reference builds are captured to compare how different Latex foam rubber manufacturers and vendors subjectively grade and use the firmness (and thickness) of Latex foam rubber manufactured by the Dunlop process or the Talalay process, using 100% natural Latex or blended Latex.

100% natural Latex foam rubber has more inherent variation in firmness (less consistent).
Talalay blended Latex foam rubber has the widest and most incremental firmness range (most consistent).
The differences in their subjective grading of firmness (super soft to super firm) may imply their experience building Latex foam rubber mattresses for actual sleep customers.
The typical comfort range is said to be 25-35 ILD, but I would shift this down to 19-28 ILD.
Latex International recommends N4-N5/30-41 ILD 100% natural Latex and 36-44 ILD blended Latex for the support core layer of a mattress. These ILD ranges are not equivalent (?). These ILDs are noted "support core" on the scales below. I would go no lower than these recommendations for the support core layer, except for a transisition support layer in a progressive construction.
The subjective grading of firmness (soft, medium, firm, xfirm), fixed layer thickness (2", 3", and 6"... seldom 1"), tautly quilted wool covers for fire retardance compliance, natural/organic greenwashing, FREE! pillows, and endless SALE ENDS SOON! sales are the nature of marketing kit Latex foam rubber mattresses.

ILD Scale (nominal ILD): LI Talalay 100% Natural (aka "All Natural")

Latex International began producing 100% natural product in 2005, presumably to compete in the green marketing space against foreign manufacturers who may have an abundant source of natural Latex (and perhaps no synthetic/blended/Talalay Latex capability).

N1 14-19 (17) plush
N2 20-24 (22) soft
N3 25-29 (27) medium
N4 30-34 (32) firm support core
N5 35-41 (38) extra firm support core

ILD Scale [density lbs.]: LI Talalay Blended/Classic Talatech (aka "Natural")

This product/scale is the reference basis for these notes and my DIY Latex mattress.

14 super plush
19 [3.2] plush
24 soft
28 medium
32 firm
36 extra firm support core
40 super firm support core
44 [10.8?] super firm support core

ILD Scale: Custom Sleep Design LI Talalay Blended/Classic Talatech

This retailer has ties to Latex International.

14 ultra soft
19 soft
24 medium soft
28 medium
32 medium firm
36 firm support core
40 extra firm support core
44 very firm support core

ILD Scale: Flobeds 100% Natural and Blended

19 ILD soft (22 ILD for 100% Natural)
28 ILD medium
32 ILD firm
36 ILD extra firm support core
44 ILD super firm support core

ILD Scale (nominal ILD) [density lbs.]: Foam Sweet Foam/Latex Green Dunlop 100% Natural

14-22 (20) [4.6] soft
23-29 (25) [4.9] medium
30-37 (31) [5.3] firm support core
38+ (36) [5.5] extra firm support core

ILD Scale (nominal ILD) [density lbs.]: Foam Sweet Foam/LI Talalay 100% Natural

14-22 (20) [3.5] soft
23-29 (26) [4.0] medium
30-37 (32) [4.9] firm support core
38+ (38) [5.3] extra firm support core

ILD Scale (nominal ILD): Sleep EZ Factory/LI Talalay Blended/Classic Talatech

This reseller's scale suggests using firmer Latex than the LI scale above for the subjective firmness of medium, firm, and extra firm.

22-24 (23) soft
30-32 (31) medium
38-40 (39) firm support core
44 extra firm support core

ILD Scale: Sleep Like a Bear/LI Talalay Blended/Classic Talatech

This reseller's scale keeps it simple.

14 extra plush
19 plush
24 plush
28 cushion firm
32 cushion firm
36 firm support core
40 extra firm support core
44 extra firm support core

ILD Scale (nominal ILD): Other

This scale is tidy and may not relate to any actual built product.

<14 (10) xxsoft
14-17 (15) xsoft
18-22 (20) soft
23-27 (25) msoft
28-32 (30) medium
33-37 (35) mfirm support core
38-42 (40) firm support core
43-47 (45) xfirm support core
>47 (50) xxfirm support core

Reference Builds: Typical Kit/Semi-Custom Latex Mattresses

Uses 2", 3", and 6" Latex foam rubber layers to construct the functional comfort layer and the support core layer. A functional layer may include one or more physical layers, i.e. a 6" support core layer can be constructed from two 3" layers.

Latex profile" (comfort layer + transition support layer + support layer).

Differential construction (no transition support layer).

6" (3+3)
8" (2+6)
9" (3+6)

Progressive construction... for progressive firmness/support.

8" (2+3+3) 3" transistion support layer (minimal 3" support layer)
9" (3+3+3) 3" transistion support layer (minimal 3" support layer)
10" (2+2+6) 2" transition support layer
11" (3+2+6) 2" transition support layer
11" (2+3+6) 3" transition support layer
12" (3+3+6) 3" transition support layer

Reference Builds: Custom Sleep Design Blended Latex Mattresses

Uses the wide and incremental firmness range of LI Talalay blended Latex foam rubber in a progressive 3-layer 2-zone construction:

The zones are a function of height and extent of spine, neck to pelvis. The lower body zone supports the hips; the upper body zone allows the shoulders to cradle (sink in) for neutral spinal alignment from neck to pelvis. The zone splice is offset 5" to allow the lower body zone comfort layer to water fall down with the upper body rib cage.
The ILD firmness is a function of weight per area and zone. The lower body zone is made progressively firmer to support the narrower hips. The upper body zone is made relatively softer to allow the wider upper body structure to sink in to for neutral spinal alignment.
Layer thickness for progressive firmness is simplified to a 2" comfort layer and a 3" transition support core layer.
2" comfort layer upper body zone: height head-to-navel + 2/3 (80 - height)"
3" transition support layer upper body zone: +5"
6" support layer: 80"

11" Latex profile (comfort layer + transition support layer + support layer)

90-129 lbs. (upper body zone | lower body zone):

2" 14 ILD super plush | 19 ILD plush Talalay comfort layer
3" 19 ILD plush | 28 ILD medium Talalay transition support layer
6" 32 ILD firm Talalay support layer

130-189 lbs. (upper body zone | lower body zone):

2" 14 ILD super plush | 28 medium Talalay comfort layer
3" 24 ILD soft | 32 firm Talalay transition support layer
6" 36 ILD extra firm Talalay support layer

190-249 lbs. (upper body zone | lower body zone):

2" 19 ILD plush | 28 medium Talalay comfort layer
3" 28 ILD medium | 36 extra firm Talalay transition support layer
6" 40 ILD super firm Talalay support layer

250-400 lbs. (upper body zone | lower body zone):

2" 24 ILD soft | 28 medium Talalay comfort layer
3" 32 ILD firm | 36 extra firm Talalay transition support layer
6" 44 ILD super firm Talalay support layer

Reference Builds: LI Pure LatexBLISS "Natural" Latex Mattresses v1, v2, v3

Uses LI Talalay blended Latex foam rubber. Version 3 (blue series) uses ActiveFUSION (formerly Celsion) phase change blended Latex formulation in the comfort layer to aid temperature regulation.

Latex profile" (comfort layer + transition support layer + support layer) Model version, plushness rating 1 to 10.
The 1" 50 ILD base layer is a handling layer and is ignored here. Note that the current v3 builds use only 2", 3", and 6" layers (the v1 and v2 1" layers have been eliminated).

Pamper... differential construction (no transition support layer).with minimal comfort and firm support; add your own topper:

7" (1+6) Pamper v1, v2, plush 5
1" 19 ILD plush Talalay comfort layer
6" 40 ILD super firm Talalay support layer
1" 50 ILD super firm Talalay base layer (was polyfoam in v1)
8" (2+6) Pamper v3, plush 4
2" 21 ILD soft ActiveFUSION Talalay comfort layer
6" 40 ILD super firm Talalay support layer
1" 50 ILD super firm Talalay base layer

Nature... progressive construction:

9" (2+1+6) Nature v1, v2, plush 8
2" 19 ILD plush Talalay comfort layer
1" 28 ILD medium Talalay transistion support layer
6" 36 ILD extra firm Talalay support layer
1" 50 ILD super firm Talalay base layer (was polyfoam in v1)
10" (2+2+6) Nature v3, plush 7
2" 21 ILD soft ActiveFUSION Talalay comfort layer
2" 28 ILD medium Talalay transistion support layer (additional 1" stiffens the progressive cradle)
6" 36 ILD extra firm Talalay support layer
1" 50 ILD super firm Talalay base layer

Nutrition... differential construction for bigger contours? (no transition support layer).

10" (4+6) Nutrition v1, v2, plush 7
2" 28 ILD medium Talalay comfort layer
2" 19 ILD plush Talalay digressive comfort layer
6" 36 ILD extra firm Talalay support layer
1" 50 ILD super firm Talalay base layer (was polyfoam in v1)
11" (5+6) Nutrition v3, plush 8
3" 27 ILD medium ActiveFUSION Talalay comfort layer
2" 19 ILD plush Talalay digressive comfort layer
6" 36 ILD extra firm Talalay support layer
1" 50 ILD super firm Talalay base layer

Beautiful... progressive construction with thick/soft comfort:

11" (3+2+6) Beautiful v1, v2, plush 9
3" 19 ILD plush Talalay comfort layer
2" 24 ILD soft Talalay transistion support layer
6" 36 ILD extra firm Talalay support layer
1" 50 ILD super firm Talalay base layer (was polyfoam in v1)
12" (3+3+6) Beautiful v3, plush 9
3" 21 ILD soft ActiveFUSION Talalay comfort layer
3" 24 ILD soft Talalay transistion support layer
6" 36 ILD extra firm Talalay support layer
1" 50 ILD super firm Talalay base layer

World's Best Bed... progressive construction with thick/soft comfort:

11" (3+2+6) World's Best Bed v1, v2, plush 10
3" 19 ILD plush Talalay comfort layer
2" 24 ILD soft Talalay transistion support layer
6" 36 ILD extra frim Talalay support layer
1" 50 ILD super firm Talalay base layer (was polyfoam in v1)
4" ? ILD ? Talalay foundation (optional)
12" (4+2+6) World's Best Bed v3, plush 10
4" 21 ILD soft ActiveFUSION Talalay comfort layer
2" 24 ILD soft Talalay transistion support layer
6" 36 ILD extra frim Talalay support layer
1" 50 ILD super firm Talalay base layer
4" ? ILD ? Talalay foundation (optional)

Reference Build: danielrhall DIY Queen 12" Blended Latex Mattress

Uses LI Talalay blended Latex foam rubber unless noted otherwise.
Him: 5'-11", 240 lbs. Prefers back/side/front?, softer.
Her: 5'-4", 130 lbs. Prefers back/side/front?, softer.

St. Dormeir Mattress Protector w/16" pocket
12" (3+3+3+3)
12” 4-way stretch-knit cotton mattress cover with zipper around three sides
3" 14 ILD (17 ILD nominal) plush LI Talalay 100% natural comfort layer
3" 22-24 ILD soft Talalay transistion support layer
3" 30-32 ILD firm Talalay support layer
3" 38-40 ILD super firm Talalay support layer

From here, the progressive cradle (314-322) seems too thick/soft and the upper support layer (330) seems too soft (Dan?).

Elements of the DIY Latex Mattress

Standard US Mattress Sizes - Twin/Single XL 38x80", Queen 60x80", King/Eastern King 76x80", California King/Western King 72x84".

Twin XL is a practical single size for a child/guest and is common in college dorms. Two Twin XLs can form a King (some Twin XLs may measure 39x80").
Queen is a practical and economical size for a couple and guest room.
Latex foam rubber cores should measure within 1" of standard US mattress sizes. If less, then the core may have been trimmed to remove edge imperfections, evident by edge encroachment on the mold pincore holes.
Twin XL and Queen Latex foam rubber cores are available as one piece with no seams, but may also be supplied with seams, so confirm exactly what you are ordering. King Latex foam rubber cores may always have a seam.

Pad/Protector - a washable, not-too-thick, stretch-knit, fitted mattress pad made of cotton/natural fibers quilted with wool to protect the mattress from debris/perspiration/stains and for ventilation. A pad is easily removed and cleaned or replaced.

A stretch-knit construction permits the pad to stretch for better comfort layer cradling.
A thick pad of fibers may compress sooner-than-later into a firmer membrane that can interfere with comfort layer cradling.
Quilted wool provides natural flame retardance and regulates body heat and moisture very well, but heavy/taut quilting can interfere with comfort layer cradling. A trampoline effect can inhibit all points sinking in, but allow bearing points to sink down, upsetting spinal alignment/support.
Recommended pad: St. Dormeir Wool Mattress Protector w/16" pocket (machine washable, thin but puffy, jersey stretch-knit, fitted, 100% cotton terry cover quilted with 16.5 oz. 100% New Zealand wool fill, 3-year guarantee).

Topper - not desired for DIY construction. May include its own cover.

A thin 1-2" topper may be appropriate for adding a missing comfort layer to an overly firm support mattress, but otherwise, a topper is a stopgap measure to fully replacing an unsuitable or broken mattress.

Cover/Ticking - a zippered, not-too-thick, stretch-knit, fitted mattress cover made of cotton/natural fibers quilted with wool to encase and protect the Latex foam rubber and for ventilation. A cover may not be easily removed and cleaned, or replaced.

Zippered access on three plus sides (around all four corners) is most convenient for accessing the layers within without fully removing the cover.
A stretch-knit construction permits the cover to stretch for better comfort layer cradling.
Quilted wool provides natural flame retardance and regulates body heat and moisture very well, but heavy/taut quilting can interfere with comfort layer cradling. A trampoline effect can inhibit all points sinking in, but allow bearing points to sink down, upsetting spinal alignment/support. If laying on the cover causes the beaded edge to pull inward against the comfort layer, then the cover is not stretching and may be interfering; unzip/remove the cover to relieve the trampoline affect.
Recommended cover: tbd.

Comfort Layer - the top mattress layer(s) to provide pressure relief, gap/secondary support, and softness/comfort (all points sinking in to distribute weight for pressure relief). Includes any pad/topper/cover thickness/firmness/quilting as active comfort layers.

Conforms/Contours to sleeping profile shape to form a cradle, filling/supporting in the gaps, especially in the lumbar/waist zone, distributing body weight as evenly as possible over the support core layer below to relieve pressure points.
Gap/Secondary support comes from the resilience/firmness in the comfort layer filling in the gaps, in balance with anti-gap point elasticity/softness in the comfort layer permitting the shoulder zone and hip zone to reach the support core layer (bearing points sinking down). Latex foam rubber resilence is very good at filling/supporting in the gaps when comfort layer thickness/firmness is properly selected, and not interfered with by heavy/taut quilting.
Average sleeping profile gaps: back ~2" at lumbar zone; side ~3" at shoulder (armpit) or waist zone (thickest/softest cradle); front ~1" at pelvis tip (thinnest/firmest cradle to prevent swayback). A smaller gap (smaller/flatter sleeping profile) requires a thinner/firmer comfort layer. A larger gap (larger/curvier sleeping profile) requires a thicker/softer comfort layer. Note that his larger flatter profile can have a gap bigger than her smaller curvier profile, simply by being the larger person with larger dimensions.
A 'heavier' person per unit area may require a thicker/firmer comfort layer. He may be heavier, but also larger, covering more area, so maybe not so much 'heavier'.
A 'lighter' person per unit area may require a thinner/softer comfort layer. She may be lighter, but also smaller, covering less area, so maybe not so much 'lighter'.
A thicker/firmer comfort layer must be simply supported by a much firmer support core layer (differential contruction; easier but less accurate results, less progressive firmness). Differential construction uses a comfort layer that is thicker than the largest sleeping profile gap.
A thinner/softer comfort layer must be assisted by a transistion support core layer (progressive construction; more difficult but more accurate results). Progressive construction uses a comfort layer that is thinner than the largest sleeping profile gap (the transition support core layer will add the missing thickness plus more progressive firmness).
The comfort layer can be soft/cushy, allowing all points to sink in while still being supported by the support core layer for neutral spinal alignment, but beware a too thick/too soft comfort layer that adversely affects spinal alignment/support.
Heavy/Taut pad/cover quilting increases thickness/firmness and can inhibit all points sinking in, especially where the sleeping profile is broad and side-by-side (upper body zones floating higher), resulting in the concentrated hip zone sinking down relatively lower as if lacking support (shoulder vs. hip balance/alignment). Evaluate the comfort layer and support layers without any quilting in place.
For special needs (large/wide upper body, small/narrow lower body) or for custom requirements, the navel-and-up upper body zone can be made relatively softer to improve cradling (sinking in) and shoulder vs. hip balance/spinal alignment... 2-zone Latex. For progressive construction, this zoning can include the comfort layer and the transition support core layer, or just the transition support core layer.
If necessary, a Queen/King comfort layer can be split down the center to vary the firmness for each side/sleeper. A split comfort layer should probably be glued/bonded to hold the seam together unless the cover is sufficiently tight.
Poor pressure relief will soon become painful and disrupt sleep (pain during the night while trying to sleep).
Recommended comfort layer for average sleeping profile: 2-3" 14-28 ILD Latex International Talalay blended Latex foam rubber (performance, quality, durability, value, availability).

Support Core Layer - the bottom/core mattress layer(s) to maintain neutral spinal alignment and firmness/primary support (bearing points sinking down/held up for neutral spinal alignment).

Proper sleeping profile neutral spinal alignment is the same as that of good, natural standing posture.
A transistion support core layer for intermediate/progressive firmness is required to assist/complete a thinner/softer comfort layer (progressive construction).
A 'heavier' person per unit area will require a firmer support layer.
A 'lighter' person per unit area may prefer a softer support layer.
For very special needs or for custom requirements, the lumbar zone or the hip zone can be made relatively firmer to limit sinking down in that area to improve spinal alignment/support... 3-zone Latex. In general, the top of the hip zone begins at the navel.
If necessary, a Queen/King support core layer can be split down the center to vary the firmness for each side/sleeper.
Poor spinal alignment will gradually fatigue and become painful (pain in the morning and longer). Back muscles will tense/clench to splint/protect sore spinal nerves.
Recommended transition support core layer for average sleeping profile (progressive construction only): 2-3" 24-36 ILD Latex International Talalay blended Latex foam rubber (performance, quality, durability, value, availability).
Recommended support core layer for average sleeping profile: 3-6" 36-44 ILD Latex International Talalay blended Latex foam rubber (performance, quality, durability, value, availability) or similar Dunlop Latex foam rubber. The typical support core layer is 6". If using two layers, the upper support core layer could be less firm and serve as the transition support core layer. A 3" minimum support core layer with no transition support layer can suffice, but the thinner mattress may be noticeable/less desirable when sitting, kneeling, and moving about; and could complicate standard mattress height and bedding considerations.

Base Layer - this handling layer is not required for DIY construction.

Skirt/Valance - a decorative fabric base cover that hangs down to the floor to hide the base and any underbed storage, and to block drafts from chilling the mattress, particularly a breathable Latex mattress on a slatted platform in cold weather.

A skirt may have only three sides, leaving the fourth side open at the headboard. A custom skirt may be required to cover all four sides of a 'floating' platform that has no headboard.
Typical skirt drops: 12", 14", 15", 16", 18", 21". A skirt should drop just short of the floor to hang freely. A mat/leg coaster can increase the drop distance; carpet pile can decrease the drop distance.
Recommended skirt: none.

Mat - a porous mat made of inert coconut fiber (coir) to allow air to circulate between the bottom of the mattress and a solid surface for ventilation and to inhibit mold and mildew.

Not required for a slatted or similar base that ventilates.
Recommended mat: Savvy Rest Bed Rug or similar coir matting product.

Base - a strong, rigid (zero-deflection), quiet (no squeaks), flat, slatted mattress platform for height, ventilation, and unyielding support. May include a bed frame/legs.

May be 1-2" smaller than the mattress size, unless it is a matching or oversized platform deck by design.
Recommended mattress height: 25-28". Dangling your feet above the floor and hopping down out of bed is not comfortable nor safe when it is dark and you are sleepy/creaky/disoriented. Examples:
12" Latex profile + 15" skirt drop/platform + 1" pad/cover/leg coaster = 28"
11" Latex profile + 15/16" skirt drop/platform + 1" pad/cover/leg coaster = 27/28"
10" Latex profile + 15/16" skirt drop/platform + 1" pad/cover/leg coaster = 26/27"
9" Latex profile + 16/18" skirt drop/platform + 1" pad/cover/leg coaster = 26/28"
8" Latex profile + 16/18" skirt drop/platform + 1" pad/cover/leg coaster = 25/27"
6" Latex profile + 18" skirt drop/platform + 1" pad/cover/leg coaster = 25"
1x6" (3/4x5.5" actual) solid wood slats with 1-2" gaps (3" gaps maximum) between the slats are recommended. Narrower slats can work, but each slat would be less rigid (more prone to deforming and breaking) and would have less area for connection/fasteners (smaller fastener pattern = weaker connection).
Capable of holding 2-3x the weight of a 100% Latex mattress (Queen 9" is ~150 lbs.) and its sleeper(s). Queen/King size should have a center support beam with additional leg support (6 legs minimum).
Bare wire grid platforms may have insufficient load bearing area and stiffness, allowing the platform to flex, develop noise, and cause wear-and-tear damage to the mattress cover.
The response of a Latex mattress is affected by its supporting base. If the base is not flat or sags, you will feel this uneven support reflected through the Latex mattress. If your base/foundation/boxsprings is suspect, you must try the mattress on the floor to be sure and to know the difference. This must come first before assessing comfort and support core layer performance.
Arched/Convex or adjustable slats are not considered here. Perhaps they are/were useful with less consistent Latex foam rubber, or for very special zoning needs.
Recommended base: a slatted platform.

***needs revision to include my current minimalist build

Average Sleeping Profile Build: DIY 7-12" Latex Mattress

Latex profile" (comfort layer + transition support layer + support layer)

stretch-knit cotton quilted with wool mattress pad
7-12" (2-3+2-3+3-6)
7-12" stretch-knit cotton quilted with wool mattress cover with zipper around three sides
2-3" 14-28 ILD super plush-medium Talalay comfort layer (zone second, if zoned)
2-3" 24-36 ILD soft-extra firm Talalay transistion support layer (zone first, if zoned)
3-6" 36-44 ILD extra firm-super firm Talalay or Dunlop support layer

***

My DIY Latex Mattress, Platform, and Pillow

His Sleeping Profile

Height of mattress: 80"
Height: 6'-2" (74" standing)
Weight: 205 lbs.
Positon(s) in order: side, front, back
Gaps: side 3.5", front 1.25", back 2.75"
Height head-to-navel (top of pelvis): 29.5" (measured laying down)
Height of upper body zone: 33" (29.5+2/3(80-74)) (rounded down)
Height of lower body zone: 47" (80-33)

Her Sleeping Profile

Height: 5'-5" (65" standing)
Weight: 145 lbs.
Position(s) in order: side, back
Gaps: side 3", back 2.5", front 1
Height head-to-navel (top of pelvis): 25.5" (measured laying down)
Height of upper body zone: 29" (25.5+2/3(80-74 his taller height)) (rounded down)
Height of lower body zone: 51" (80-29)

My Proposed Build: DIY Queen 8-11" Blended Latex Mattress (needs revision)

Given LI Talalay blended Latex foam rubber.

Similar to the CSD 190-249 lbs. 3-layer 2-zone progressive build except: i) uses his firmness on both sides; ii) has only a 3" (not 6") and firmer support layer. The 19 ILD x 5+" comfort layer foot zone is required if cutting the 28 ILD pieces from a single Queen 28 ILD layer. It will comfort the boney heel/ankle/toe and ease the cover a bit for contouring.

Upper | Lower body zone dimensions are given for his/her sides. Zone seams are not bonded.

St. Dormeir Mattress Protector w/16" pocket
9-11" (2+3+3-6)
9" or 12" stretch-knit cotton quilted with wool mattress cover with zipper around three sides
2" 19 ILD plush x 33"/29" | 28 ILD medium x 42"/46" | 19 ILD plush x 5+" Talalay comfort layer
3" 28 ILD medium x 38"/34" | 36 ILD extra firm x 42"/46" Talalay transistion support layer
3" 40 ILD super firm Talalay support layer (optional)
3" 44 ILD super firm Talalay support layer

My Current Build: DIY Queen 6" Blended Latex Mattress

Uses LI Talalay blended Latex foam rubber.

St. Dormeir Mattress Protector w/16" pocket
6" (3+0+3)
9" cotton quilted with bamboo/wool mattress cover with zipper around three sides (does not stretch, but loose fitting)
3" Rejuvenite stretch-knit cotton topper cover with zipper around all four sides
3" 19 ILD plush x 33"/29" | 28 ILD medium x 42"/46" | 19 ILD plush x 5" Talalay comfort layer (his/her zoning)
3" 44 ILD super firm Talalay support layer

Comments:

Starter kit build was 328-336-344 in a high quality but stretchless quilted wool cover. Had pressure relief and spinal alignment issues, especially for him. Surface was too hard; support was too soft.
Added the stretchy wool pad. Good protection, contouring, and ventilation.
Added a Rejuvenite 3" 19 ILD topper to experiment with shuffling 3 and 4 layers around. Educational but not a solution. 19 ILD inside the mattress cover provides a comfortable surface firmness for the sensitive upper body areas, but the taut cover still causes pressure relief issues. 319-328 is too deep/soft of a cradle; support/alignment suffers.
Zoned the upper body zone to increase sinking in to improve upper body pressure relief; and to increase sinking down to improve shoulder plunge and shoulder vs. hip spinal balance. But still not supportive enough.
The topper cover inside the mattress cover softens the surface and holds the comfort layer zones together, but the mattress cover is still taut and causes pressure relief issues. So, the cover top was removed, folded, and stored under the mattress.
Conclusion 10/8/13: Burying the base support under too many layers of too soft foam does not/can not work. It ruins the platform support you want and need. Instead, start with the base/platform (floor) and add just enough foam to create the cradle. Done! I now have a 3" zoned comfort layer on a 3" support core layer (differential build) in a loose, contouring cover. It's very comfortable and supportive (soft and firm). I can sleep side, front, and back.

Spare material:

19 ILD and 28 ILD pieces from Queen layers; and a 36 ILD Queen layer.

My DIY Queen 18" Radiata Pine Platform

This Latex mattress platform is simple and strong and looks nice, but it was a challenge to design, assemble, and finish because of the thin and long dimensions, the inset removable legs, and the soft wood. The GRK RSS fasteners are absolutely awesome fasteners and are perfect for this softwood design. The custom pipe legs are simple and very strong for a leg attached to soft wood with one bolt and are perfect for this softwood design. A few simple materials and tools and good design came together to make this project a success.

5x60x80" one-piece slatted platform deck cantilevered over (6) 13" removable pipe legs inset on a 44x54" c/c footprint. The mattress floats in space over recessed legs. Headboard/Footboard can be added, but are not desired. The design can be used for a Twin XL with (4) legs and a King with (8) legs (two Twin XLs attached).
18" skirt drop/platform with option to cut the legs down to 11" for a 16" skirt drop/platform.
13.75" (or 11.75") clearance for underbed storage.
(12) 1x6" top slats with ~1.25" gaps fill 80".

Deck 5x60x80"
(12) top slat Radiata Select Pine 1x6x60" (6') $10.55
(6) rail Radiata Select Pine 5/4x4x80" (8') $13.75
(2) bottom slat at end Radiata Select Pine 1x6x50.5" (6') $10.55
(2) bottom slat at legs Radiata Select Pine 1x8x50.5" (6') $12.84
(168) GRK Fasteners RSS Structural Screw #10x2.5" (1/8" bit thru 1x6 only; no pilot in rail)
(24) GRK Fasteners RSS Structural Screw 5/16x3.125" (5/32" bit thru 1x8; 1/8" bit short pilot in rail)
(2) Minwax Tung Oil Finish 1qt. (2 coats, no stain) $19.87
(1) Blue Nitrile Disposable Glove 50cnt. $7.97
(2) Wiping Cloth 55cnt. $10.97

Legs 4.5diax13"
(6) Hex Bolt 5/16x5.5" $0.52
(6) Fender Washer 5/16x1.25" $0.29
(12) Fender Washer 5/16x1.5" $0.24
(6) Fender Washer Plastic 5/16x1.5" (custom fab)
-- bottom slat at legs --
(6) Fender Washer Plastic 5/16x5.5" (custom fab)
(6) leg PVC Pipe Schedule 40 Solid Core 4x13" (10') $17.19
(6) leg Insert PVC Pipe Schedule 40 Solid Core 3.5x3" (from 10') (custom fab)
(1) PVC Cleaner Clear 8oz. $7.21
(1) PVC Cement Clear Heavy Duty 16oz. $9.60
(6) leg Insert Plywood Maple 3/4x4"dia.
(6) T-Nut Pronged 5/16-18x3/8 $1.04
(6) leg coaster felt 3/8x6"dia. (custom order) $24.99 total

Tools
4x8' work table or similar level area for square layout and assembly (the most difficult part!)
tape measure
12" miter saw (chop saw)
saber saw for leg inserts and large plastic washer
3/8" drill; 1/8", 5/32", 5/16" bits
1.75" hole drill bit for small plastic washer
180, 220 sandpaper and block
(4) 30" pipe clamps
scrap pine clamping blocks
scrap PVC Pipe Schedule 40 Solid Core 3x10" for molding leg insert
Acetone and wiping cloth to remove PVC Pipe printing

My DIY Queen 100% Natural Shredded Latex Pillow

A "FREE!" solid Latex pillow is nearly useless, like sleeping on a balloon, but a shredded Latex pillow can be adjusted to perfection and serves very well in all sleep positions: back, side, and front.
I hand-shredded (pinched apart) some solid LI Natural Latex Pillows to mini-marshmallow-size fill (smaller is better) and then adjusted the fill in the pillow case until I could side sleep without developing neck pain caused by the pillow being too thick or too thin (bent neck/spine).
If you change the mattress layer firmness, you must adjust the fill in the pillow (a firmer surface requires a taller pillow since your body will float higher in the cradle while the pillow tends to float the same).
Forget free and useless solid Latex pillows... buy LaNoodles by the Pound and make your own shredded Latex pillows. Consider using a St. Dormeir Wool Pillow Protector to match your mattress pad, or a less expensive Lands' End pillow protector or similar.

Related Links

Manufacturers

Duroflex, India
Latex Green, Sri Lanka (Dunlop)
Latex International, USA (Talalay)
Latexco, Belgium, Indonesia, Spain, USA (Dunlop, Talalay)
Radium Foam, Netherlands (Talalay)
Richard Pieris & Company (ARPICO), Sri Lanka (Dunlop)
Sapsa Latex, France, Italy, USA (Dunlop)
Thai Rubber Latex Corporation, Thailand (raw Latex)
Yulex Corporation, USA (biorubber)

Vendors

This message was modified Oct 8, 2013 by GKDesigns

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