Mattress Toppers Made in the USA, Poured in Phoenix, Arizona

The Phoenix factory

LOUNJ Bedding was founded in 2018 by Nat Holfeltz, who had spent 15 years in the bedding industry watching foam get poured in one country, cut in another and sold by a brand that never touched it. He started a family-owned foam plant in Phoenix, Arizona to do the whole thing under one roof.

Today that is still how it works. Liquid foam components are mixed and poured in our Phoenix facility, cured, and sun-baked in the Arizona heat, which drives off the new-foam odor before the topper is ever boxed. The cured buns are cut to size on our own equipment, in stock sizes from Twin to California King, in 12 RV sizes, and in any custom rectangle up to 80 x 84 in half inch increments. Covers are sewn in house. Orders are compressed, boxed and handed to FedEx from the same dock. When you call (800) 556-1333, you reach the people who made your topper.

What “made in USA” means for foam, and what it does not

Foam is a chemical product, so where it is poured determines where it is made. Many toppers sold as American are imported foam cut, covered or packaged domestically. That is assembly, and it changes nothing about the density, chemistry or certification of the foam.

LOUNJ gel memory foam is poured in Phoenix from start to finish. That gives us control over the two things that decide how a topper performs: density, which determines whether it holds its shape for years or packs down in months, and formulation, which determines what you are breathing at night. We make ours without fiberglass and without fire-retardant sprays.

We are also plain about the parts that are not domestic. The fabrics for our covers, including the bamboo cover on the Tri-Zone Topper, are sourced from mills around the world, then cut and sewn into finished covers in our Phoenix factory. Our Talalay latex is natural latex that we cut and finish here. The foam you sleep on is American made; the cover fabric is sewn here from globally sourced textile.

CertiPUR-US: what the certification actually checks

Made in USA tells you where. CertiPUR-US tells you what. It is an independent certification for flexible polyurethane foam, and every LOUNJ memory foam topper carries it. Certified foam is tested by accredited labs and must be:

• Made without ozone depleters
• Made without PBDE, TDCPP or TCEP flame retardants
• Made without mercury, lead or other heavy metals
• Made without formaldehyde
• Made without phthalates regulated by the Consumer Product Safety Commission
• Low in VOC emissions for indoor air quality

Because we pour the foam ourselves, the certification applies to the foam in your topper, not to a supplier’s foam that may or may not have made it into a given batch. Our Talalay latex is Oeko-Tex certified, a separate standard for textiles and latex that tests the finished product for harmful substances. Both are hypoallergenic and low odor.

Why factory direct and American made go together

Making the foam here is only affordable if we also sell it here, directly. A domestic factory that sold through importers, distributors and retailers would price itself out of the market against overseas foam. Selling factory direct removes those margins, so an American-made LOUNJ topper lands at a price that competes with imports, without the corners imports cut. Our affordable mattress toppers page explains that comparison in detail.

It also means faster shipping. Because every topper leaves from Phoenix, orders placed by 2pm Arizona time Monday through Friday ship the same or next business day by FedEx Ground, free to the lower 48, and arrive in 2 to 3 business days. Custom sizes get a written quote in 1 to 2 business days and most ship within a week of approval. A supply chain that fits in one building is a supply chain that does not run out of stock in a shipping container somewhere.

The whole line is made here

Everything we sell comes out of the same Phoenix factory. Gel memory foam toppers in 2, 3 and 4 inches: the bare Gel Mattress Topper, the covered Gel Mattress Topper 2.0, the 2-layer Firm Mattress Topper and the zoned Tri-Zone. RV toppers in 12 RV sizes and the RV Mattress with its charcoal cooling cover. Talalay latex toppers cut to order. Adjustable and body pillows filled with shredded gel memory foam clusters, Talalay latex pillows, and bulk shredded foam fill in 5 to 40 pound bags.

Every topper, pillow and fill is backed by a 5-year warranty, and mattresses by 10 years. Every stock item comes with the 30-Night Happiness Guarantee, free returns, no fees. That is easy to offer when you know exactly what went into the product, because you made it.