Memory Foam Mattresses Require Engineering and Research to Develop a Quality Product
The Memory Foam manufacturing process is a significant procedure that requires specialized engineering and knowledge. Beware of discount memory foam manufacturers as it takes quite a considerable investment in time and money to cultivate a quality product.
Memory Foam has two basic manufacturing methods.
Poured Mold Cooling
The oldest and most common method consists of simply pouring liquid foam into a mold and allowing it to cool. The quality of the foam produced while not defective can produce mattresses with an inconsistent density (more on density later). This is because the aggregates within the foam mixture are not evenly distributed in the mold.
Vacuum Injection
A more recent approach used by the brands like Sleep Aid incorporate a process called Vacuum Injection. Vacuum Injection is a procedure by which the liquid foam is poured into an air tight mold and then the air within the mold is removed so that a vacuum is created. The temperature at which the foam cools is also controlled. This allows the cooling foam to expand evenly in all directions, preventing dense areas from forming within the foam.