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Custom 3-Layer Mattress

Layered foam mattress
Ordering details:
  • For custom enter dimensions to nearest  1/2″.
  • Enter thickness of each layer to nearest 1/2″.
  • Top (1) and Bottom (3) can be the same for a reversible mattress.
  • Select Foam Type of your choice. The last two numbers of the foam type represent the firmness or compression – see foam types.
  • You can choose something softer or firmer based on your preference.
  • Select a mattress cover from the available cover options below.
  • Add an optional Fireshield Barrier and HealthGuard Mattress Pad to protect your mattress and keep it clean.
  • Other custom sizes and natural options are available at Foamite.
  • What you should know about Mattress Warranty.

HealthGuard Mattress Pad and Health Protector

Keep your mattress cover safe and clean with this Natural Bamboo terry cotton stretch cover. Designed with elastic sides and a rubber band on the bottom, it fits a variety of mattress thicknesses effortlessly.

This product serves as both a mattress protector and a health shield, boasting a washable and 100% waterproof design. It safeguards your mattress from spills and stains that could impact your warranty. 

Constructed from soft, breathable organic fibers, this material effectively combats dust mites, mold, mildew, fungus, and bacteria. The bamboo fabric naturally wicks away moisture for a more comfortable night’s sleep while regulating temperature to keep you cooler in summer and warmer in winter.

This highly durable product comes with a 5-year warranty. It is recommended by doctors for reducing allergens and managing asthma, allergies, and eczema.

A)Pick a Size
Width (side to side)
Length (head to foot)
* If custom size is chosen then please enter width and length above.
B)Thickness
1. Top Layer
2. Middle Layer
3. Bottom Layer
C)Select Foam Type for Each Layer
1.
2.
3.
D)Firm Edges
E)Join Pieces
F)Select a Cover
G)Fireshield Barrier
H)HealthGuard Pad
I) Order Details
Unit Price
$44.20

Fireshield Barrier

This is a unique natural fire barrier that encases the foam under the cover. It safeguards against open flames and prevents the foam from catching fire or allowing flames to spread. When the flame is taken away, it self-extinguishes, providing a safe alternative free from harmful fire retardant chemicals. Read more>

Quality Part No. Description Density
(lbs/cubic foot)
Firmness Price / Board Foot
Cut to Size Sheets
Economy 1030This is the cheapest, lightest-grade foam, commonly found in toppers for spring mattresses, cheaper pillows, and the outside backs & arms of furniture 1.0 lb. WhiteMedium $1.39 $1.39
1338With a density of 1.3 lbs, this foam is denser and firmer than the 1030 version. 1.3 lb. WhiteMedium Firm $1.59 $1.59
Basic 1515For higher-quality backs or mattress toppers, use the 1515 foam. It’s also ideal for basic seating applications, such as office chairs, dinette seats, or furniture commonly found in flea markets or discount stores. While it comes at a lower cost, its performance level is also more basic. It’s suitable for Sofa Bed mattresses or more durable camp mattresses designed for heavier use. 1.5 lb.
White
Soft $1.75 $1.48
1530 Medium $1.75 $1.48
1535 Medium Firm $1.75 $1.48
1545 Firm $1.75 $1.48
Good 1925This foam line is commonly chosen by furniture manufacturers who supply high-quality furniture to reputable stores. It offers excellent value for a conventional foam, making it ideal for seating and bedding applications, including full foam mattresses. Stores consider it the best in its class. We take it a step further by using superior foam, which is why our mattresses are of higher quality. 1.9 lb.
White
Medium $2.15 $1.82
1932 Medium Firm $2.15 $1.82
1938 Medium Firmer $2.15 $1.82
1943 Firm $2.15 $1.82
1955 X-Firm $2.15 $1.82
Curon HD C2130This foam is a preferred choice in the Upholstery trade for its superior seating comfort. It also makes an excellent mattress core, which can be paired with High Resiliency foam, Natural Latex, or Memory Foam toppers. The Curon brand has been a trusted name for over 35 years, known for its outstanding performance and comfort, especially when compared to other polyurethane foams. The firmness rating is based on a 4 to 5-inch cushion. For thicker applications, use lower compression foams, and for thinner uses, opt for higher compression options. 2.1 lb.
Blue
Medium $2.46 $2.09
C2135 Medium Firm $2.46 $2.09
C2145 Firm $2.46 $2.09
C2165 XX-Firm $2.75 $2.35
Premium HR HR18The highest quality High Resiliency (HR) foam, proudly made in Canada, is designed for superior performance. HR foam is denser, ensuring it maintains its thickness and firmness much longer than traditional polyurethane foams, which tend to soften with use. The HR18 and HR22 grades are ideal for premium, softer backs and seats, and can also serve as durable toppers for added comfort. This line is a bit heavier than standard Premium HR and comes in both Super Soft and Firmer Compressions. All Premium grades are non-allergenic, CertiPUR-US certified, and free from harmful chemicals or substances. With minimal off-gassing, they are a healthier choice compared to imported offshore foams often used in boxed mattresses sold online or in big box stores across Calgary and Alberta. 2.6 lb.
Peach
Soft $4.15 $3.89
HR22 Medium Soft $4.15 $3.89
HR26 Medium $4.15 $3.89
HR31 Medium Firm $4.29 $3.64
HR35 Medium Firm $4.29 $3.64
HR41 Firm $4.29 $3.64
HR51 X-Firm $4.29 $3.64
HR61 XX-Firm $4.65 $4.09
Dry Fast (Outdoor Foam) DF32Dry Fast Outdoor Foam is the perfect choice for outdoor cushions that face the elements. If you’re using water-repellent fabric, consider also using Premium HR Plus foam for added durability. Both foams are resistant to mold and mildew, ensuring long-lasting comfort and protection. 1.8 lb.
White
Medium $7.39
DF48 Firm $7.39
Other Types 1570COften used for a wide variety of packaging applications. 1.5 lb. CharcoalXX-Firm $2.35
1590Commonly used in Ottomans and exercise mats. 1.5 lb. WhiteXX-Firm $2.02
2295A step up in quality from the 1590, but just as firm. 2.2 lb. SilverXX-Firm $3.15
HR10Memory foam-like feel with improved air circulation and pressure point relief, offering benefits similar to HR foam. 3.0 lb.
Light Green
Super Soft $5.15
Memory Foam MF3010Memory foam blended with cooling blue gel for improved temperature regulation. 3.0 lb.
Light Blue
Soft $5.00
VG4012Memory Foam with swirls of cooling blue gel 4.0 lb.
Blue Swirls
Super Soft $7.15
Colour of Different Foam Types (Click on foam to see bigger picture)
VG12 Memory
Premium HR
Curon HD
Dry Foam
1030 to 1.9 lb.
1570C Charcoal
Organic Cotton
Organic Cotton Cover
See Bigger Picture

This cover is only available in a 10″ thickness in Extra Long Single, Queen and King sizes.

The Organic Cotton Euro-Top Cover is made from pure organic cotton. Only natural untreated materials are used to make this cover.

The cover is made with two separate compartments with zippers that house the topper and core separately. This way you can change either or with ease and continue with the same mattress for years to come.

When you sleep on our Organic Mattress, you will not only receive a high-quality, well-designed product, you will also be sleeping on a healthier surface and supporting environmentally responsible production methods.

Silver Pure
Silver Pure Cover
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This cover is only available in a 10″ thickness in Extra Long Single, Queen and King sizes.

Silver Pure technology uses the bactericidal action of silver which is a powerful natural antibacterial agent that destroys bacteria.

The silver ions that are embedded in this fabric are very active against dust mites, bed bugs, bacteria, and other household allergens. Silver is used and well-known to safeguard the purity and hygiene of your mattress.

Allergy Doctors who were involved in testing were so impressed by the results that they have started recommending Silver Pure to their patients for allergy relief, hygienic purposes and better sleep quality.

Cooler Extreme
Cooler Extreme Cover
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This cover is only available in a 10″thickness in Extra Long Single, Queen and King sizes.

This new cover fabric offers excellent bi-elastic properties, for memory foam mattresses, and maximum air flow and circulation.

It also enhances the properties of such modern comfort ingredients as: Koosh ViscoGel and the coolest NeoGel topper. The easy-care fabric is equally as good as it is highly functional. It can be stretched both ways.

This cover is made with Friesen thread which is 42% cooler than cotton. It also contains Dacron, a fibre with unique fast-drying properties, that helps to dissipate heat and moisture from your sleep surface.

Simon Adjustable
Simon Adjustable Cover
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This cover is only available in a 10″ thickness in Extra Long Single, Queen and King sizes.

The Simon cover is a natural textile made from wood pulp cellulose. A versatile natural cover that maximizes the benefit of each foam layer.

The different zones are marked to highlight the unique layering of simon mattress. Moreover, The production process is also free from harmful chemicals or any substances that could damage your health or the environment.

Simon Adjustable Cover is made with the highest thread count and uses a new knitting technique to create the impression of quilted fabric. There is no light-weight fibre in the lumbar area that sag and create body impressions.

Grey Vine Quilted
Grey Vine Quilted Cover
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The Grey Vine quilted 2-sided cover is reversible. The quilting will add 1″ to the overall thickness in the centre of the mattress.

This fabric is very durable. It is imported from Germany and made with one of the highest thread counts for mattress fabrics.

The Grey Vine fabric uses a new knitting technique to create the impression of a 3D quilted fabric without using any light-weight foam or fibre that can compress pre-maturely and show body impressions.

It is particularly suitable for people with sensitive skin thanks to its silky and smooth surface. It also helps to create an extraordinarily warm, dry and comfortable sleep surface.

Bamboo Anti-Microbal
Bamboo Anti-Microbial 2-Sided Quilted Cover
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The Bamboo A.M. cover is highly permeable by air and has a high heat-regulating capacity, making ideal for superior air circulation.

Bamboo Anti-Microbal is a natural option to Dacron fabric which has been used in dry-fit sports clothing. It will maintain a cooler sleep surface.

It is made with fabric that offers unique and fast drying properties. Allows superior air flow and quick dry moisture. The fabric is sewn to the highest standards of quality.

It is a reversible two-sided quilted cover. The quilting will add 1″ to the overall thickness of your mattress. Bamboo also has many anti-bacterial properties that are retained throughout its life.

SOLD OUT
EcoComfort Quilted
EcoComfort Quilted​ Mattress Cover
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The EcoComfort 2-sided quilted cover is reversible and made with eco-friendly fabric that is free from any harmful chemicals or substances.

The secret behind EcoComfort’s success is the unique pore structure within its yarn which increases the fabric’s surface area by 8 times.

This means that any moisture that meets the fabric spreads out further and quickly evaporates. This will lead to a dry sleep surface and help to improve your quality of sleep.

This cover can be used with reversible mattresses. The quilting in the fabric will add one-inch to the overall thickness of your mattress. It is easy care fabric and made with a very high thread count.

Visco Natura Quilted
Visco Natura Cover
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This natural eco-friendly cover is only available in an 8″ thickness for Single, Double, Queen and King size mattresses.

It is a premium cover that is made with viscous fibres which are derived from a tree’s cellulose which is also known as Tencel.

At 320 grams this fabric has a very high thread count which exceed most covers that are only 230 grams in weight. It is thicker and heavier making it much more durable.

It is an off-white colour and soft to the touch because of its high viscous content. Unlike cotton, this cover provides improved moisture retention and evaporation due to its unique nanofibril technology.

SOLD OUT
NorthStar Blue Quilted
Mattress Covers Toronto
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The NorthStar quilted two-sided cover is reversible. The quilting will add 1″ to the thickness. Easy-care fabric that is highly functional.

Thanks to this innovative process, the fabric stretches and returns to its original position. It also absorbs moisture and dissipates heat.

This new cover fabric offers excellent bi-elastic properties and maximum air flow. It can be stretched equally in both directions so that it adopts optimally to your body’s curves.

This material is very durable and highly functional. The quality and softness of our covers is very evident when you compare them to lighter weight fabrics that are commonly found in most mattress stores.

Grey Vine Unquilted
Grey Vine Unquilted 1-Sided Cover
See Bigger Picture

This fabric is very durable. It is imported from Germany and made with one of the highest thread counts for mattress fabrics.

This cover is highly elastic, very flexible and made with fabric that has a high restoring force to maintain the shape of your mattress core.

The Grey Vine fabric uses a new knitting technique to create the impression of a 3D quilted fabric without using any light-weight foam or fibre that can compress and show body impressions.

It is particularly suitable for people with sensitive skin thanks to its silky and smooth surface. It also helps to create an extraordinarily warm, dry and comfortable sleep surface.

Bamboo A.M. Unquilted
Bamboo A.M. Unquilted 1-Sided Cover
See Bigger Picture

This cover is one-sided and unquilted. It is highly elastic and very flexible; therefore, it works well with memory foam type mattresses.

It stretches to take the shape of your body and then returns to its original shape. This ecological product is made with 100% biological materials.

Natural eco-friendly fabrics have been growing in popularity because they have many unique properties and are more sustainable than most textile fibres.

They are soft as silk, strong as polyester, cool as linen, warm as wool, more absorbent than cotton and to some extent antibacterial. The cover is not reversible, but the mattress core is.

SOLD OUT
EcoComfort Unquilted
EcoComfort Unquilted​ Mattress Cover
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Similar stretch material as the Bamboo textile. It is also highly elastic and very flexible; therefore, it works well with memory foam mattresses.

It stretches to take the shape of your body and then returns to its original shape. One-sided unquilted cover with anti-skid base.

This cover is great when used in combination with our eco-friendly foam options like our Ecocell, Preserve, Koosh Natural or Koosh ViscoGel memory foam. This is an ecological product that is made with materials that are 100% biological.

It is a bi-elastic cover that stretches in every direction. The base is made with a waterproof anti-slip material.

Chemsafe Blue Nylon
Chemsafe Blue FR Nylon Unquilted 2-Sided Cover
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Our Chemsafe Blue Nylon mattress ticking is made with a 210 Denier nylon and has a one-ounce fluid resistant polyurethane coating.

Chemsafe Nylon cover is easy to clean and maintain. It is flame retardant, for both the NFPA 701 and CAL 117-2013 Fire specifications.

It is softer than our thicker commercial grade vinyl. The waterfall flap, over the zipper, prevents liquid from seeping into the foam core and contaminating the inner part of the mattress.

It is bed bug resistant, and very durable. It is commonly used in nursing homes, or medical applications for its superior waterproof characteristics and ease of cleaning.

Commercial Vinyl
Commercial Taupe FR Vinyl Unquilted 2-Sided Cover
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This cover uses premium 32oz automotive grade FR vinyl which is a fluid proof antibacterial surface barrier for your foam mattress.

Commercial Vinyl is used for overnight camps, therapeutic massage tables, correctional and institutional dormitory facilities.

This vinyl is flame retardant and designed to be soft and comfortable yet remain its strength and long-lasting durability. Due to the thickness of the vinyl this cover will make your mattress feel firmer.

For this reason, we recommend that you choose a slightly softer foam compression when considering this type of cover. It is taupe in colour and easy to wipe down.

Commercial Cotton
Commercial Cotton Unquilted 2-Sided Cover
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Durable Commercial cotton Cover is used for applications such as hotels, motels, dormitories, camp and cottage mattresses.

It is a reversible cover with alternating double blue and white stripes. It is not quilted with fibre and it is not made with harmful fire retardants.

All our covers are made with a long 3-sided zipper for easy replacement of the outer cover or the foam core inside. Most mattresses in stores are made with closed covers so that you can not see inside.

Mattress covers are important, but they are not as critical as what they cover. That is why we have more foam than covers and truly believe, “That Its What’s Inside That Counts!”

Terry Cotton
Terry Cotton Cover
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Terry Cotton covers are an inexpensive way to protect the foam from getting dirty or ripping. It is mainly used for topper applications.

It is only available in 2″ to 4″ thickness for a Double, Queen and King sizes. It can be used in ½” increments (i.e. 2.5″ thick).

It is also available for 8″ to 10″ thick Double size mattresses. These covers can be used for custom sizes that are close to the sizes given above but they can not be altered to fit the custom sizes perfectly.

Terry cotton has a high level of water absorption, it is quick drying and has an excellent soft surface texture. This terry fabric cover will stretch to fit thicker or slightly larger sizes.

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Mattress Warranty

If you buy a mattress from us, and you have a problem, we will focus on a solution rather than dwelling on the problem. You can bring your mattress back to our Vaughan Factory, for as long as you own it, and we can re-work it for a fraction of the cost of buying a new mattress. Its better for you and the environment.

As a manufacturer of custom foam mattresses, that are made with better quality foam, we can honestly tell you that most retail mattress warranties are not worth the paper they are written on. We know this because foam is the key comfort ingredient used in all mattresses and as a foam manufacturer, we know foam.

Conventional spring mattress retailers warranty their mattresses against the spring core from breaking or bending out of shape. That rarely happens, instead what is a common occurrence is the sagging of the top comfort layers. However, if you were to call them on it, they would tell you that this is “normal wear” and not covered by warranty.

Spring Mattresses are mostly filled with air and made with lightweight comfort ingredients that
sag prematurely. This is considered "normal wear" and not covered by warranty.

This is why the biggest complaint at our Vaughan Factory Showroom, about competitor’s mattresses, is that “my 20-year warrantied mattress has only lasted 3 or 4 years, and it is not covered by warranty”.

The foam mattress sellers also follow a similar approach. Foam mattress warranties cover the mattress from sagging more than 1.5” in thickness. However, the warranty does not cover the softening of the foam, which will leave you sagging into the mattress and cause back problems due to the lack of support. When you call for warranty, they will tell you that this is “normal wear” and that all foam does that.

This is true but all foam is not created equal and you should know that that High Resiliency foam does not sag or soften as quickly as the conventional polyurethane grades that are used in mattresses that are sold in stores or that are compress rolled into boxes and sold online.

For more detailed information please see – Mattress Warranty.

Ergocheck Testing

An overly firm seat or mattress creates uncomfortable pressure points (above) that cause restless tossing and turning. The right firmness (below) is more relaxing and restful.

Ergocheck Testing uses a specially designed pad with hundreds of tiny sensors that measure the physical pressure between the body and a specific seat or mattress firmness. Although it is predominately used to choose the right mattress firmness the results can be used as a guideline for seat cushions as well. Choose a firmness based on your weight, preference and the test results.

For example, if you weigh between 140 to 180 lbs, you would fall in the medium category. Your firmness options (the last 2 numbers of the foam) would be between 24 and 30 ILD (Indentation Load Deflection). You can choose lower or higher in your range or from the next range based on your preference, foam thickness, and the intended use of the foam.

Keep in mind, Back Foam does not need to be as firm as a Seat Foam because it does not support as much weight. Also a seat needs to be firmer than a mattress because there is more weight concentrated in one spot.

If you go too far from your weight range or too firm, you will get uncomfortable pressure points that will cause you to toss and turn excessively and prevent you from sitting or sleeping comfortably.

Fireshield Barrier

"It's an obvious choice..."

Foamite’s Fireshield barrier is made of silica fibers, akin to the sand particles used in glass production. This material is naturally flame resistant. Although it can burn when directly exposed to a flame, it is difficult to ignite and will self-extinguish once the flame is removed. The same materials used in the Fireshield barrier are often found in high-performance protective gear for firefighters.

This flame-resistant material also features excellent textile qualities, such as durability and a soft hand feel. It utilizes the same fiber system employed by the U.S. military for the undergarments of combat troops

Every day one person dies in a bedroom fire

When it comes to safety, open-flame resistant mattresses are as important as the role airbags played in vehicles a decade ago. With someone in the United States dying every day in a bedroom fire (according to the U.S. Consumer Products and Safety Commission), many involving children, we can’t wait for regulations to make safer foam available. Prioritize safety: consider adjusting thickness or cover quality, but be sure to invest in a fire shield barrier for your mattress. It’s a clear choice.

Recognized by the Children’s Coalition for enhancing fire safety in mattresses, the Fireshield material is composed of fibers that have been certified in accordance with California Proposition 65.

What's a Fireshield™ Barrier?

This fire barrier operates independently, surrounding the foam under the mattress cover to improve the safety of fire retardant foam. It offers protection from open flames and stops both the ignition of the foam and the spread of fire.

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Winter Shutdown Notice

  1. Our Factory will be shutdown from Dec 23rd until Jan 1st, 2024.
  2. Regular shipping and pickup will resume on Tues Jan 2nd.
  3. PLEASE NOTE: You can still order over the Winter Shutdown, but we will not be able to process your order until our return on Jan 2nd.
  4. CONFIRMATION AND AVAILABILITY: We will email you when your order will be available for pickup.
  5. Thank You for visiting our site.

Online Payment

Order Availability

1
Processing vs. Shipping Time

Processing time is the time it takes to get your order ready to leave our factory. This includes receiving the pattern (for pattern cuts), cutting the foam, fabrication, performing quality checks and packing for shipment. Processing times are displayed below:

  • Foam cut to size minimum 3 hours from time of order
  • Foam that is wrapped with fibre (5 days or less)
  • Mattress size (foam only) or pre-made stock mattresses (2 Days or less)
  • Standard size layered mattress with cover (10 Days)
  • Custom sized mattress, including boat mattress, with cover (15 Days)

Shipping time is the time for your item(s) to travel from our factory to your destination.

2
Quicker Pickup Available
  • We stock all our foam types in block form
  • You can request a quicker 3-hour pickup in the checkout page
  • Your order will be ready 3 hours after it is placed
  • Factory location – 1000 Edgeley Boulevard Vaughan, ON
  • Business hours – Monday to Friday from 9:00 am to 5:00 pm
  • We are closed for lunch from 12:30 pm to 1:00 pm
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3
Delivery Quote
  • All foam and mattresses are compressed and roll packed to keep the cost of delivery down
  • All foam orders are processed and shipped within 5 days of receipt
  • Add your address information in the cart page for a quote on delivery