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I had a very positive experience recently when building a memory foam mattress using foam bought online from The Foam Factory at www.foamdistributors.com (and also at www.foambymail.com) I made a queen size memory foam mattress. I wanted a high quality but inexpensive version of a Tempurpedic-type mattress. But since it was to be used in a furnished rental apartment, I made some slight changes to the usual plan (described below), in order to make it more sanitary and more durable and more flexible in design. I called the Foam Factory company to ask some questions, they were helpful. I ordered online, no problems, packages arrived promptly, intact, and the foam they sent was the foam I ordered. And believe me, I checked: You see, before ordering I had searched this forum and the fatwallet forum and found some old posts from 2007 or so in which people complained that they had ordered 5 lb memory foam from the Foam Factory and had weighed the packages before opening and found them to be lighter than expected, the assumption being that the company accidentally sent a lower density foam than the customer had ordered. Then the customer returned the foam, which is a huge hassle, I should think. I emailed Foam Factory right after ordering and told them that I had heard of this old problem, and I am sure that is has been resolved, and that I have done the calculation and I am expecting my 4” queen 5 pound ViscoMax memory foam topper to weigh just over 55 pounds, (give or take a little variability factor): Density times cubic feet equals weight: 5.0 lbs/cubic ft times 60 inches (1/12) X 80 inches (1/12) X 4 inches (1/12) EQUALS 55.556 POUNDS The weight on the UPS label said 55lbs. I weighed the package and it was 56.5 lbs in the box. I removed the box and the memory foam wrapped in plastic weighed 55.1 lbs. Cool. So, I can affirm that the foam factory is selling true 5 (pound-per-cubic foot) density “ViscoMax” memory foam, just like they advertised. (At least on their web site they are: you see, they also sell memory foam cheaper on ebay and call it “5 lb,” but it is really 2.5 lb because they divide by 2 cubic feet instead of one. This is clearly stated in their ebay ad, if you know what you are reading.) So buy from the Foam Factory website for the denser stuff. I also ordered 2 sheets of conventional foam as a base. These are advertised on the web page to be 2.8 pcf density. 2.8 lbs/cubic ft times 60 inches (1/12) X 80 inches (1/12) X 3 inches (1/12) EQUALS 23.333POUNDS These foam sheets came in separate boxes, one weighed 23 lbs and the other 24 lbs, so again, Foam Factory sent me what I ordered. I am pleased. Here is what I used to make the mattress:
Bottom Base Layer: 3 inches queen “LUX High Quality” conventional foam, $94.25 from www.foamdistributors.com (50 lb compression, FIRM base layer) Middle Base Layer: 3 inches queen “HD36 High Quality” conventional foam, $94.00 from www.foamdistributors.com (35 lbs compression, Medium Firm base layer) Top Memory Foam Layer: 4 inches “5 pound density ViscoMax” memory foam, $219.99 from www.foamdistrbutors.com or from www.foambymail.com
Now, most people at this point would just buy a velour (AKA “terrycloth”) cover from ebay and put it right on the memory foam directly. But like I said, this mattress is for a rental unit, so I wanted it to be sanitary for multiple users and durable. So, on top of the foam I put a vinyl fitted sheet that is open on the bottom. (They also make one that covers the entire bed like a zippered bag, but I left the bottom foam uncovered by vinyl for breathability and so as not to create a “balloon full of air” vinyl "bag.") Then, on top of the vinyl fitted sheet I put a zippered bag-type cover that encloses the entire mattress, but instead of the soft velour ones I used a tougher natural cotton zippered bag, again, for more durability. It can be removed and washed, but it takes some effort to get off the heavy mattress since the zipper only opens on the one end (see photos). Actually, it wasn’t too bad to get on the mattress, really. The vinyl helped it slip on better, I guess. The natural cotton enclosure was labeled as 9” deep, but it turns out that it fits loosely on this 10” mattress (see photo) so I might wash it in an effort to get it to shrink down a little snugger. On top of that I used a conventional quilted fitted mattress cover, and then a fitted flannel sheet. Vinyl Cover, $11.95 Natural Cotton enclosure, $23.45 ($16.50 plus shipping of $6.95) Total cost of queen memory foam bed: $443.64 Evalation: It is awesome! I love it. It is firm and supportive, but my pressure points (hip and shoulders, side sleeper, 250lbs, 6ft 1” tall male) sink into the memory foam and make a body-shaped dent. Great mattress! I can sit on the edge to put socks on, it supports that with no problem. The Memory foam layer has a 10 year warranty and an estimated “longevity” of about 25 years, on the website. I’m not sure what warranty the 2 conventional foam layers have. But note that I didn’t buy the regular quality foam for the base layers (HD36 – Regular and LUX – Regular), I bought the higher quality versions (HD36 – High Quality and LUX – High Quality), which are only listed on www.foamdistributors.com. I could have saved money buying the “regular” version of the 2 base layers, but they are only rated to last 5 – 8 years, whereas the more expensive “High Quality” base foam layers I ordered are each rated to last 12 – 18 years. So why didn’t I just buy a memory foam mattress at Costco? I tried, I looked. But mine is better. Costco might occasionally have a queen one on sale for $500 or so (never less), but when you read the components list it does not seem as good as what I got. Look at this one from Costco: $499.99 after $100 OFF Novaform® Item # 565448 But in reading the Costco web page I saw that its top memory foam layer is only 2.5 inches! The rest of the 12” mattress is conventional foam! And who knows what density the memory foam part even is? Why didn’t I just order the pre-made Memory foam bed from Foam Factory with the 4” of 5 lb ViscoMax memory foam on top? Well, yes, it would have cost about $75 less than what I made, and it comes glued together, which is convenient to some people. So I might do that in the future if I need a good, cheap bed again. But my arrangement is more flexible, since it is not glued. Firstly, I wouldn’t know which 5” base to choose on the pre-made bed, HD36 (Medium Firm) or LUX (Firm)? So I ordered both, each 3”. So, my bed is 10” whereas the pre-made one is 9”. If it is too firm or if someone lighter sleeps on it, a new layer of soft foam can be added just below the memory foam (using convoluted foam or latex perhaps). If firmer is desired, then the LUX base can be moved to the middle. If the base wears out before the memory foam, a new base can be put in. Also, it is easier to move, since it weighs 100 lbs, but can be moved in 3 pieces. Besides, I could always glue the layers together with spray glue if I really want that. Here are pictures to tell the story described above: http://www.flickr.com/photos/67752868@N03/ (I couldn't figure out how to get the photos in this post, so just look on my flickr. The photos are in reverse chronological order so start on page 2.) This message was modified Apr 7, 2012 by Mattress_Project
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Thanks for this would you say it's firm or do you really sink in? I'd really like to know a detailed impression of the pink foam thanks |
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blueoakleyz wrote: Thanks for this would you say it's firm or do you really sink in? I'd really like to know a detailed impression of the pink foam thanks That said, I think it is great. My whole body makes a shallow dent in the foam, maybe an inch or so, and then the real pressure points sink in deeper, to maybe 3 inches in those spots only (hips go in deepest, then shoulders next deepest). I am a side sleeper, 250lbs male 6'1". I have bought 1 or 2 inch memory foam toppers in the past from stores (unknown density) and when I tried them I thought, "What was the point?," because my body flattened the thing right away. Yes, I have read on forums people saying that 4" of the 5lb memory foam would be too much. But I figured, "not for me," I WANT to sink in". I want to sink in and feel I am on a memory foam bed, not just think, "what was the point of buying memory foam?" Before I had ever tried memory foam a friend told me he bought a Tempurpedic and that he went to sleep in a certain position and woke up 7 hours later in that same position. That is what I want, or close to it. I used to switch sides about every hour on a hard bed I had (because of shoulder pressure against the bed), so hopefully on this new one I will turn only 2 or 3 times per night? We'll see. So far I really like the mattress I made, as described in my original post above. Good luck. Read the forums, think about it, but eventually you have to just go for it. |