Journey of a Mattress Cover: From Fabric to Final Bedding

Published 19th January 2026

From initial design ideas, through international fabric sourcing, to final delivery across the world, the journey of a mattress cover is more complex than you might think. But rest assured, with mattress manufacturing from Redwood, you’ll get expertise, experience and innovation added in at every stage.

Let’s take a look at the mattress manufacturing process, and the journey of your designs from the drawing board to the hospital ward, the shop floor or your hotel beds.

Step One – Expert Specification and Design

Before a metre of fabric is bought, cut or sewn, our design team will sit down with you to establish exactly what you need. With Redwood mattress manufacturing, there’s no such thing as a standard mattress. Every customer is different, with their own budgets and quantities, performance requirements and regulatory compliance demands.

Our expert design, development and quality compliance team can work with you whether you have a complete specification or just an outline idea of what you need. This collaborative process ensures that when we start your mattress manufacturing, every detail has already been agreed upon, and nothing is left to chance.

Step Two – Sourcing High-Performance Technical Textiles

At Redwood, we never fit our mattress manufacturing projects to the textiles we happen to have to hand. We source the fabric specifically for each project, to meet your exact specifications without compromise. 

Redwood is part of a global textile group, and we can source fabrics from textile markets around the world to match your budget and your needs. This includes the very latest advances and innovations in technical textiles, finishes and fabrics.

Step Three – Precision Cutting 

Having set the design and sourced the fabric, the next stage is precision cutting. This is essential for two reasons: firstly, to ensure fabric sections are cut accurately, to within fine tolerances, and secondly, to get the maximum value from every roll.

Redwood has the very latest fabric cutting equipment to deliver optimum fabric cutting, including:

  • CNC-controlled single and multi-layer cutting machines

  • Programmable laser cutters

  • Narrow hot and cold cutting 

  • Skilled manual cutting

Step Four – State of the Art Assembly 

Once the fabric is cut, your mattress manufacturing enters the final stage, where seams are sealed or stitched, and the mattress cover is completed. This is not a time to compromise, as high-quality mattress cover seams are essential for performance and durability, as well as providing specialist features such as waterproofing and bacterial resistance.

Redwood offers a wide range of mattress cover seam options, including:

Our expert team will advise you on the best seam option for your end use. 

Step Five – Quality Assurance 

Every member of the Redwood mattress manufacturing team is an expert in their field, and when they combine their skills, you get quality without compromise at every step. Nonetheless, we still monitor that quality throughout the process, demanding the very highest standards and never settling for second best.

No mattress cover moves on to the next stage until it has been cleared by quality control, and no finished product leaves our factory until we are satisfied that it will meet and exceed your expectations. That’s why we’re ISO9001 certified for quality.

Step Six – UK and Worldwide Delivery

The final leg of the journey for your covers is from our mattress manufacturing plant in Skelmersdale to you. Redwood has its own delivery fleet, and we are perfectly placed, right in the heart of the UK motorway network. We can deliver fast, or we can store your products ready for just-in-time delivery, saving on storage space on your end.

Redwood also delivers worldwide, with Liverpool Docks and two airports all within easy reach for international orders.

Join us on the journey

The journey of a mattress cover, from design to delivery, is a long and complex one. But with Redwood in control, you can be sure that every step will be successful. Work with us, and we’ll get you to where you need to be on time, on budget and without compromise.

To find out more about Redwood mattress manufacturing, for medical, retail or hospitality, get in touch with our team today. Your journey starts here…

Frequently asked questions about mattress manufacturing

Medical mattresses usually require PU coated fabrics, as these are waterproof yet breathable. These can be enhanced with fire resistance, anti-bacterial properties and more, to keep patients safe and comfortable. As technical textile experts, Redwood can offer a wide range of high-performance fabric options.

Manufacturing times vary depending on the complexity of the cover and the manufacturing processes required. Since we manufacture here in the UK, Redwood can often produce and deliver mattresses and mattress covers faster than an overseas manufacturer.

Yes. Redwood has the equipment and the expertise to create exactly what you want, in exactly the size you want it. We love a challenge, so never be afraid to ask.

Choose sewn mattress covers for comfort and breathability, usually for domestic or hospitality bedding. Choose welded seams for waterproofing and infection control in medical settings, like hospitals and care homes. Each has its advantages, and Redwood’s expert design team will be happy to advise on the best seam for your mattresses.


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