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Sealy research & development

The science behind Sealy

We strive to ensure that your mattress is rigorously tested and designed to last, and that your Sealy product looks and feels the same on day 3650 as it does on day 1.

Crash test dummy with green spine lies on their side on a Sealy mattress

Sealy research & development

What do we measure?

Every Sealy mattress is built to specific criteria set by the Orthopaedic Advisory Board. We measure our construction methods, designs and prototypes to ensure they offer correct support and optimal comfort in line with these requirements. 

We also conduct quality assessments on our components and materials. We strive to produce mattresses that deliver exceptional performance for years to come. The intersection of comfort, support and durability is the foundation of our Posturepedic Criteria and it is what makes our mattresses unique.

The importance of R&D

We are proud to have a unique and diverse team in R&D with extensive technical knowledge and industry experience. Hailing from varied disciplines, the team includes designers, engineers, scientists, project managers, mechanical specialists, upholsterers and more.

From ensuring that the comfort of each mattress is as exceptional as possible, to testing the sturdiness of the mattress edge or the durability of the mattress itself, Sealy’s Research and Development team strive for nothing less than perfection.

With the only accredited mattress test lab in the country, we take R&D seriously. We are constantly working on developing better beds to help people all over the world get a better night’s sleep.

What do we measure?

Comfort layers

Your Sealy mattress is designed to cushion your pressure points and minimise any impact on your body. We use this research to develop mattresses with optimal comfort layers for deep, refreshing sleep.

Pressure mapping test

This test is performed by lowering a manikin onto a sensor mat. Using specialist software, we measure the performance of the mattress in terms of pressure distribution.

Essentially, we are able to see whether it has sufficient cushioning. If the amount of pressure is too high, it indicates that the mattress is not offering appropriate comfort. 

Cornell test

Our Cornell device presses into the mattress with 102kg of force 100,000 times. This test is the equivalent of someone sitting in the same spot over and over again.

We do this to see how the materials stand up to continual pressure. The height and comfort of the mattress should not be compromised beyond an acceptable amount, even after years of use.

Partner disturbance test

We use weighted rollers to measure the amount of disturbance caused by a partner shifting or moving during the night.

This allows us to assess our mattresses against real-world interactions and consumer needs. We take this information and create solutions with improved performance, designing beds for minimised disturbance and improved rest.

What do we measure?

Support systems

We test our support technology to ensure it promotes correct spinal alignment. In addition, we ensure our comfort layers, construction methods and designs work in harmony with our coils to offer correct support.

Rollator test

Our rollator barrel moves across a mattress 200,000 times in a single test. Weighing 110kg, it helps us to understand the impact of a person shifting and moving on a mattress. Additional fatiguing occurs with the hexagonal shape.

Once the test is complete, we measure changes in the structure and height of the mattress. In order to pass, the mattress must meet certain criteria so that we know it can withstand 10 years of use.

Spinal alignment manikins

Sealy mattresses are designed and built to specific criteria. We know from our research with orthopaedic surgeons that the best sleeping posture is the same as when we are standing upright.

We use SAMs, spinal alignment manikins, to simulate the way a human body interacts with a mattress. We measure the angles of their bodies as they lie down and assess the mattress against strict support requirements.

Robot seated test

One of our robots is specially designed to sit on the edge of a mattress and ‘hop into bed’. It slides across the surface of the mattress the same way most people do at home, applying constant pressure.

This process is repeated 5,000 times before we check for any changes in height or feel and assess internal components. It allows us to understand how the mattress will perform in the home for a decade of typical use.

What do we measure?

Quality and durability

We conduct testing on every component and material that goes into a mattress, including panel fabrics, handles, comfort layers, edge supports and springs.

Foam firmness test

We measure the performance of our foams in a number of tests to get an understanding of their firmness and overall quality.

We do this to ensure that our foams offer the right amount of comfort and durability. We also check for any foreign additives in the foam that could compromise its integrity, striving for material consistency.

Tumble pilling test

One of our fabric tests involves taking samples and running them in a cork drum for 90 minutes. The drum creates surface fussing and rubbing. 

We assess the samples afterwards for pilling or tears. The textiles we use need to withstand expected stresses during manufacturing, moving, and years of use in the home without compromising on quality.

Pilling test

This machine runs for 10,000 cycles, repeatedly rubbing a fabric sample across an abrasive surface. It is designed to simulate years of wear and tear.

Once the test is complete, we check for any ripping, pilling or deterioration. We do this to ensure that our panel fabrics are smooth and pristine for the full life of the mattress, whether it is at home or on the shop floor.

Mattress selector

Not sure what mattress is right for you?

Discover your perfect mattress by using our mattress selector tool.

Simply answer a few questions and we’ll recommend the right mattress based on your unique sleep profile. We will email you your customised results so you can take them in-store to a Sealy retailer near you.

Model sleeps comfortably on Sealy mattress with flowers beside bed


Don’t take our word for it

Five million Australians choose to sleep on a Sealy.
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