The MAZZU mattress

Benjamin Hubert, Founder of design studio LAYER, talks about their recent project with MAZZU as they engineered a new sustainability-focussed mattress concept.

Earlier this year, LAYER, a thought leading design studio working across strategy, industrial design, engineering, branding and digital design, formed a partnership with MAZZU’s engineering team to create a groundbreaking new product typology that prioritises sustainability and intuitive UX. The result, the MAZZU mattress.

LAYER has designed a revolutionary foamless, modular mattress for start-up sleep brand MAZZU. The new system combines ultimate adaptability and repairability with the elevated comfort of a regular sprung mattress. LAYER says that the design challenges the conventions of the mattress industry, with a focus on sustainable materials and a unique modular construction that significantly prolongs the product lifespan and reduces waste.

The MAZZU mattress, which officially launched at IMM Cologne in January this year, is created by assembling “modular pocket springs”, comprised of an hour-glass spring wrapped in a seamless, two-tone, 3D-knit textile that creates a melange sleeve, and a recyclable connecting system. The modular pocket springs are available in three different tensions – Firm, Medium, and Soft – allowing users to intuitively build a mattress to suit their sleeping position. This also allows the two sides of the mattress to be individually configured to suit the different needs of couples.

“We conducted intensive user research around the world to determine the needs of different sleepers, and used these insights to shape the final product,” Benjamin Hubert, Founder of LAYER, said. “We also developed a reusable packaging system to ship and then store the mattress.

“The individual spring modules are attached together with a secure “snap-fit” connection and combined with a Base Matrix and comfortable Cushion Topper to create a versatile mattress that can be configured and repaired as needed to fit all frame sizes in every country. Once assembled, the mattress has an open structure that proudly displays the spring system to create a distinctive and ownable identity when desired.”

The MAZZU mattress is made from “skin-friendly and sustainable materials” – including organic wool, recycled polyester, natural latex and recyclable polymer – which provides comfort and support while eliminating the use of glue and foam.

“The use of PU foam in the mattress industry is a major cause of concern – both environmentally and for our health,” adds Benjamin. “According to studies released in 2018 and 2020, approximately 60 million metric tons of mattresses are discarded worldwide each year and more than 90% of mattress components are not recyclable. Additional research has shown that PU foam is not only energy intensive in production, but also produces volatile organic compounds (VOCs) that are harmful to our health and wellbeing. The MAZZU mattress aims to overcome these issues with a completely foam-free, glue-free construction.”

The MAZZU spring modules can be compressed from a height of 250 mm to 50 mm, allowing for efficient shipping and convenient storage in a compact, reusable packaging system. A small double mattress, for example, can be compressed from a volume of 0.6m3 to just 0.12m3 – a reduction of 80%.

The modular nature of the MAZZU mattress not only means it can be disassembled for storage, easy cleaning, and replacing of individual modules. New modules can also be combined with existing modules so that the mattress can grow as needed.

“We’ve been working with MAZZU for the last three years, and have been so impressed with their commitment to driving a groundbreaking, sustainable system for sleep,” says Benjamin. “The bedding industry needs step changes in the way it thinks about delivering high-performance products whilst being mindful of the planet and MAZZU are leading the way in contributing to that dialogue.”

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