Mattress types keep evolving, and the machines behind them must keep pace—or get left behind.
There are four main types of mattress spring machines—Bonnell, pocket, continuous coil, and offset—each serving different production needs based on support type, comfort goals, and market positioning.
Choosing the right machine directly impacts your mattress line’s efficiency, cost, and market appeal. Let’s break them down.
What Are the Primary Types of Mattress Springs?
Market demand shapes the machines you need.
Mattress spring types define comfort levels, motion isolation, and long-term performance. Understanding each type helps you choose the right machine for your product line.
| Spring Type | Shape/Feature | Ideal For |
|---|---|---|
| Bonnell | Hourglass coils | Budget and mid-tier mattresses |
| Individually encased coils | Premium, motion-isolated comfort | |
| Continuous Coil | One-piece interconnected coils | Economical, long-lasting support |
| Offset | Squared-top coils with hinging | Zoned support, multi-position sleepers |
Let’s dive into the machines that build each one.
How Do Bonnell Spring Machines Work?
The workhorse of the spring world.
Bonnell spring machines produce hourglass-shaped coils, coiled from wire and knotted at each end, then laced into units. These machines are widely used due to their simplicity and high-speed output.
Key Features:
- Wire fed, coiled, and knotted
- Springs automatically assembled into rows
- Ideal for high-volume production
Applications:
- Budget-friendly mattresses
- Entry-level exports
- High-rotation hotel and dorm markets
Why Choose It?
Fast output, low cost, and long-proven performance.
What Makes Pocket Spring Machines So Specialized?
Precision engineering for high-end comfort.
Pocket spring machines coil wire, compress the spring, insert it into fabric sleeves, and thermally or ultrasonically seal the pockets. Springs are then glued or sewn together in rows.
Key Features:
- Independent coil movement = no motion transfer
- Customizable spring count, height, and gauge
- Multi-zone layouts programmable
Applications:
- Hybrid mattresses
- Orthopedic and pressure-relief beds
- Premium export products
Why Choose It?
They sell better—and at higher margins.
How Do Continuous Coil Spring Machines Improve Efficiency?
One wire. Hundreds of springs.
Continuous coil machines form springs from a single wire strand that loops through and connects each coil. It’s the most material-efficient design.
Key Features:
- Lower scrap wire
- Minimal raw material joints = high strength
- Faster production cycle vs. pocket springs
Applications:
- Value mattresses
- Rental or institutional beds
- Markets with price sensitivity
Why Choose It?
Low input costs, quick throughput, solid support.
Where Do Offset Spring Machines Fit In?
The sweet spot between bounce and body contour.
Offset machines form squared-off coils, typically joined with hinging helical wires. This configuration creates a flexible, supportive feel.
Key Features:
- Reduces roll-together sensation
- Offers targeted lumbar and edge support
- Often combined with reinforced frames
Applications:
- Adjustable beds
- Zoned orthopedic mattresses
- Mid to high-end domestic lines
Why Choose It?
Blends the resilience of Bonnell with the contouring of pocket springs.
What Role Do Computerized Spring Machines Play?
Custom production? It starts here.
These machines use touchscreens and PLCs to control tension, coil count, pitch, and wire diameter—often with AI-based auto-calibration.
Key Features:
- Program batch recipes (e.g., 3-zone spring units)
- Auto-adjust tension per coil
- Store multiple SKU settings
- Integrate with cutting and gluing stations
Applications:
- Smart factory production lines
- Mixed product plants (multiple mattress types)
- Export compliance needs (EU/US specs)
Why Choose It?
Scalable flexibility with higher QC accuracy.
How Do Automation and Integration Affect Production?
It’s not just about springs—it’s about speed, precision, and coordination.
Spring machines today are built for integration. They connect to conveyor belts, glue stations, and mattress assembling lines.
Integrated System Benefits:
- Faster line speeds = higher daily output
- Fewer workers needed
- Auto reject + auto stacking = lower error rates
You’ll also see lower wire waste, tighter quality control, and real-time production tracking.
Quality Control and Durability: What’s Built In?
Modern machines test spring tension, load, and consistency as they run. Sensors flag off-tolerance springs for rejection before they enter the mattress.
Key checks include:
- Tensile strength
- Coil height uniformity
- Weld/bond integrity
Quality assurance = fewer complaints, fewer returns, more repeat buyers.
Conclusion
Whether you’re producing budget innersprings or high-end hybrid cores, your spring machine is the backbone of your mattress line. Choose based on spring type, quality targets, and production scale—because every machine shapes not just coils, but your bottom line.