Abstract: A mattress and method and system for making said mattress having a mattress casing 1 having a quilted top sleep panel (2) wherein one or more layers of high density foam (3) are stacked and quilted between an outer layer of fabric (4) and an inner layer of fabric (5). The high density foam is preferably Talalay foam and the panel may have multiple layers of high density foam and other materials such as wool, cotton batting and so forth. The inner layer of fabric, outer layer of fabric and at least one layer of high density foam are secured or quilted together by placing a plurality of stitched lines (7) across the area of the panel. The method and system of the present invention allows the high density foam to be continuously quilted without sewing needles being deflected or binding occurring.

Abstract: A mattress and method and system for making said mattress having a mattress casing 1 having a quilted top sleep panel (2) wherein one or more layers of high density foam (3) are stacked and quilted between an outer layer of fabric (4) and an inner layer of fabric (5). The high density foam is preferably Talalay foam and the panel may have multiple layers of high density foam and other materials such as wool, cotton batting and so forth. The inner layer of fabric, outer layer of fabric and at least one layer of high density foam are secured or quilted together by placing a plurality of stitched lines (7) across the area of the panel. The method and system of the present invention allows the high density foam to be continuously quilted without sewing needles being deflected or binding occurring.