Foam Forward: The Innovation Behind The Casper Mattress

By Alyse Borkan  |  Apr 18, 2017
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New products launch every day. But it’s not every day a team spends 9 months visiting 15 factories to understand the properties of hundreds of materials before they do it. Casper’s engineering team has been obsessively researching, testing, and learning long before day 1. But here’s the most remarkable part — they never stopped.

The Casper mattress became an instant hit. The iconic blue and white striped box popped up in the US and soon traveled to doorsteps across the world. The mattress racked up awards as prestigious as TIME’s Best Invention of 2015, and a Which best buy of 2017. Regardless, the engineering team never stopped wanting to create an even more perfect night of sleep.

They grew from 1 to 30 and have spent the last 800+ days (and nights) testing and implementing the most intricate changes to make the Casper mattress better than ever — never letting a sale or an accolade curb their drive to innovate.

Wondering what’s different about the Casper mattress since day 1?

  • There is a new, fourth transitional layer between the top two comfort foam layers and the firmer durable base foam. When you lay down, you push through the layers, compressing the top comfort layers until you really start to push into the base layer. This feel as you push through the layers of a mattress is colloquially called “Ride.” Generally, you want as smooth a Ride as possible. Any inflection points or changes in firmness can affect comfort, especially for larger weight people and side sleepers. The new 4-layer mattress proved to have a smoother Ride, softening the mattress at its deepest layers to relieve even the slightest pressure.
  • We partnered with a renowned polymer chemist, so that the Casper would maintain its comfort at a wider temperature band. Usually, visco memory foams (what we use as our second layer) get hard at 60F. The tricky part is the lower temperature band you have, the more fragile the foam becomes, so you can end up sacrificing durability for comfort. We found a way to get our temperature band to go down to 40F, while still maintaining the Casper’s durability — a true feat in the foam world.
  • We changed the chemistry of the base foam at the molecular level. We test our foams day in and day out to understand the expected softening and keep it below a human-perceptible level. Foam density is indicative of the expected life of a foam, and not all foams are created equal. The higher the foam density, the longer they’ll retain structural integrity — minimizing softening.

And this is just the beginning. Our product engineering team works day and night to continue to study the mattress, conduct endless sleep research, and work to create the most revolutionary night of sleep. Make sure you stay tuned to continue to learn what our team is dreaming up.

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