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Case Study
Replacing Coconut Fiber With a 3D Mesh Mattress
In 2013, Chinese maternity brand KUB approached us looking for a new children’s mattress solution to replace traditional coconut fiber structures. Existing mattresses often had odor problems during humid seasons, limited airflow, and overly hard sleeping surfaces for babies and children.
Our Solution
Product Solution
1
Proposing a Fully Breathable Mattress Structure
To improve airflow and sleeping comfort, we proposed a fully layered 3D spacer mesh mattress structure. Mefiss Textile, our own spacer mesh fabric factory, supplied different spacer mesh materials for both the sleeping surface and internal support layers.
2
Creating Softer Surface Comfort
For the top sleeping surface, we used 7mm thick T2D-53 spacer mesh fabric made with DTY yarn. The smoother and finer mesh texture created a softer skin-contact feeling while maintaining breathable performance suitable for direct sleeping use.
3
Building Strong Internal Support Layers
Inside the mattress, we combined three layers of 20mm thick T2S-6Q high-strength spacer mesh structures. The dense support yarn system improved rebound stability and pressure support while significantly increasing airflow efficiency compared with traditional dense materials.
4
Upgrading Toward a Glue-Free Structure
During the early production stage, environmentally friendly glue was used for structure lamination and edge reinforcement. Later, through continuous structure optimization and sewing improvements, we gradually upgraded the mattress into a fully glue-free breathable structure solution.
Results
What We Achieved
The all-3D mesh mattress later became one of the important breathable alternatives to traditional coconut fiber mattresses in the Chinese maternity and children’s market.
