Foam Mattress Market - Global Industry Size, Share, Trends, Opportunity, and Forecast, 2021-2031

The Global Foam Mattress Market is projected to expand from USD 48.86 Billion in 2025 to USD 64.44 Billion by 2031, reflecting a CAGR of 4.72%. This market consists of sleep surfaces crafted from viscoelastic, latex, or high-density polyurethane materials that are engineered to conform to the body and reduce pressure points. Key factors propelling this growth include rapid urbanization and growing consumer recognition of the link between quality sleep and long-term well-being. Additionally, the rise of the direct-to-consumer model, particularly through streamlined "bed-in-a-box" logistics, has significantly improved market accessibility and lowered distribution expenses for manufacturers.

Despite these positive indicators, the industry confronts significant hurdles regarding the instability of raw material costs, especially for crude oil-derived isocyanates and polyols. Volatility in petrochemical prices can drastically squeeze profit margins and interrupt supply chain reliability for producers. For example, the European Association of Flexible Polyurethane Foam Block Manufacturers (Europur) reported that production of flexible slabstock polyurethane foam in Europe fell by 2.7% to 893,200 tonnes in 2024, driven by stagnant demand and escalating operational expenses. This decline underscores the foam sector's continuing susceptibility to broader economic fluctuations and variations in input costs.

Market Drivers

The swift growth of online retail and direct-to-consumer sales channels has transformed the global foam mattress sector by removing intermediaries, enabling brands to provide competitive pricing. This logistical evolution aids broader market reach, especially for compressed foam items designed for efficient shipping. Although the wider industry deals with volume issues - evidenced by the International Sleep Products Association reporting in 2024 that the U.S. mattress market's total wholesale value dropped to $9.8 billion for the full year of 2023 - the direct-to-consumer sector continues to be a vital path for resilience and global expansion. As a case in point, Tempur Sealy International’s 'Third Quarter 2024 Results' from November 2024 revealed that international net sales via the direct channel rose by 10.6% year-over-year, illustrating enduring consumer demand for buying directly from manufacturers despite a slow economic climate.

Concurrently, the escalating demand for sustainable and bio-based foam mattresses is spurring considerable innovation in material recovery and circular economy strategies. As environmental rules become stricter and consumers become more aware of landfill waste, manufacturers are focusing on the recyclability of polyurethane foams and the use of sustainable materials. This transition is demonstrated by the growing success of end-of-life management initiatives aimed at reclaiming foam for supply chain reintegration. According to the Mattress Recycling Council's '2023 Annual Report' released in July 2024, the organization collected nearly 1.5 million mattresses in its program states, diverting roughly 60 million pounds of steel, foam, and other materials from waste streams, driving producers to develop foams that are both ergonomic and environmentally responsible.

Market Challenges

The instability of raw material costs, specifically regarding crude oil derivatives like isocyanates and polyols, represents a major obstacle to the growth of the global foam mattress market. Manufacturers rely heavily on these petrochemical inputs for creating viscoelastic and polyurethane foams, rendering them extremely sensitive to abrupt changes in oil prices. When the cost of raw materials surges, producers are forced to either absorb the expense, which reduces profit margins, or pass the cost to consumers, resulting in higher retail prices. Such price increases inevitably diminish product affordability, causing consumers to postpone purchases and leading to a reduction in overall demand.

This financial uncertainty interrupts supply chain consistency and hinders long-term investment planning for manufacturers, thereby directly slowing market expansion. The effect of these cost-related challenges is reflected in recent market performance figures. As reported by the International Sleep Products Association, the wholesale value of mattress shipments in the United States was projected to fall by 4.5% in 2024, as the industry struggled with enduring inflationary pressures and weak consumer demand. This downturn demonstrates how the sector's vulnerability to input price fluctuations directly limits shipment volumes and revenue growth.

Market Trends

The adoption of advanced cooling and phase-change materials has emerged as a key competitive advantage as manufacturers respond to consumer needs for temperature regulation. This trend extends beyond simple open-cell designs to include high-conductivity gels and proprietary grid technologies that actively disperse body heat. The market is seeing an increase in designs that layer hyper-elastic polymers over foam to improve airflow and temperature neutrality, directly addressing the heat retention problems traditionally linked to viscoelastic foam. This shift is supported by recent financial results; for instance, Purple Innovation reported in its 'Third Quarter 2025 Results' from November 2025 that net revenue reached $118.8 million, driven by robust shipments of its Rejuvenate 2.0 collection featuring a specialized cooling gel grid, confirming that effective thermal management is now a primary value driver for high-end foam sleep systems.

Furthermore, the integration of AI-powered sleep tracking and automation is reshaping the value proposition of foam mattresses by evolving them into active health monitoring tools. Manufacturers are increasingly incorporating contactless biometric sensors within foam layers to monitor sleep metrics and facilitate real-time adjustments to firmness and temperature. This technological merger is drawing substantial investment and shifting the sector's focus from passive comfort to active wellness management. According to an August 2025 article in Pulse 2.0 titled 'Eight Sleep: $100 Million Raised To Advance AI-Based Sleep Optimization', the company obtained $100 million in Series D funding to expedite the rollout of its autonomous sleep improvement technologies, highlighting the industry's move toward intelligent sleep platforms that use machine learning to customize the user experience and enhance rest quality.

Key Players Profiled in the Foam Mattress Market

• Magniflex
• Hilding Anders International AB
• Breckle GmbH
• Sleep Number Corporation
• RUF Beds GmbH
• Pikolin S.L.
• Sealy Corporation
• Simmons Bedding Company LLC
• Silentnight Group
• Serta, Inc.

Report Scope

In this report, the Global Foam Mattress Market has been segmented into the following categories:

Foam Mattress Market, by Type:

• Memory Foam
• Latex
• Others

Foam Mattress Market, by Distribution Channel:

• Offline
• Online

Foam Mattress Market, by Region:

• North America
• Europe
• Asia-Pacific
• South America
• Middle East & Africa

Competitive Landscape

Company Profiles: Detailed analysis of the major companies present in the Global Foam Mattress Market.

Available Customization

The analyst offers customization according to your specific needs. The following customization options are available for the report:

• Detailed analysis and profiling of additional market players (up to five).

This product will be delivered within 1-3 business days.