Americanstar Mattress Launches U.S. Foam Manufacturing to Speed up Innovation and Strengthen Retailer Margins » BedTimes Journal
NEWS RELEASE
(February 17, 2026) WACO, TX — Americanstar Mattress, the Texas-based sleep innovation firm identified for delivering premium consolation with robust retail margins, introduced as we speak the launch of in-house foam manufacturing at its Waco, Texas, manufacturing facility.
The transfer brings greater than 20 years of world foam-pouring experience to U.S. soil for the primary time, enabling Americanstar’s U.S. staff to develop and refine proprietary consolation applied sciences particularly for American customers—whereas accelerating velocity to marketplace for its retail companions.
For retailers, the implications are rapid: entry to differentiated product improvements rivals can’t replicate, delivered at worth factors that defend wholesome margins and drive sell-through efficiency.
In a market the place private-label copycats and direct-to-consumer manufacturers compete aggressively on worth, proudly owning foam manufacturing offers a degree of product differentiation and price management most manufacturers merely don’t have.
From International Experience to U.S. Execution
The Americanstar Group has operated as a vertically built-in mattress producer for greater than 25 years, producing merchandise for retailers and distributors in over 30 international locations. Foam manufacturing has lengthy been central to that mannequin, with the corporate pouring its personal proprietary foams internationally for greater than 20 years.
That confirmed functionality is now operational at Americanstar’s Waco facility, the place the corporate is actively producing foam on-site—bringing formulation growth, testing, and manufacturing nearer to the U.S. market and its retail companions.
“We’ve been pouring our personal foam for greater than 20 years—this isn’t new territory for us. What’s new is bringing that experience to our U.S. operations,” stated Tony Nguyen, Chief Working Officer at Americanstar US. “By manufacturing foam in-house at our Waco facility, we will transfer sooner on innovation, management high quality at each stage, and create consolation applied sciences which might be purpose-built for what U.S. customers need—and what our retail companions have to win on the ground.”
SilkFoam™ Know-how: The Innovation That Proves the Mannequin
Americanstar’s proprietary SilkFoam™ Know-how is the clearest instance of what in-house foam experience makes potential. Born from the corporate’s deep expertise in foam formulation, SilkFoam™ is a responsive materials with a silk-like texture that delivers weightless consolation and stress aid—providing responsiveness and contouring efficiency that differs from each conventional reminiscence foam and latex.
SilkFoam™ has grow to be a cornerstone of Americanstar’s U.S. product technique. It’s at present featured throughout a number of collections, together with the best-selling Presidential Hybrid Assortment, the Cleopatra Assortment, and the newly launched S-Class Hybrid Assortment—every of which has demonstrated robust sell-through efficiency and excessive client satisfaction.
Every assortment reinforces the business worth of proprietary materials innovation, giving retailers differentiated product tales that assist stronger shut charges and better ticket values.
“SilkFoam™ is an ideal instance of what occurs while you management the science behind the supplies,” Nguyen added. “It’s not one thing we supply from a catalog—it’s one thing we created as a result of we perceive foam chemistry at a basic degree. With U.S. foam manufacturing now operational, we’re positioned to develop much more improvements that give our retail companions an actual edge.”
What Home Foam Manufacturing Means for Retailers
By bringing foam manufacturing in-house within the U.S., Americanstar strengthens its capability to ship on the worth proposition retailers have come to depend on:
Proprietary improvements retailers can’t discover elsewhere
In-house foam formulation permits Americanstar to develop unique consolation applied sciences—like SilkFoam™—that differentiate retail flooring and provides gross sales associates a compelling, science-backed story to inform.
Quicker velocity to market
Home manufacturing reduces lead occasions and provide chain complexity, enabling sooner product launches and faster response to evolving client demand.
Stronger margins by lean manufacturing
Vertical integration—from foam pouring to completed mattress—reduces prices throughout the manufacturing chain. These efficiencies translate into aggressive wholesale pricing and the form of wholesome retail margins that matter in as we speak’s compressed surroundings.
High quality management from the bottom up
Proudly owning the froth manufacturing course of ensures consistency and high quality at each degree, lowering defects, minimizing returns, and delivering dependable efficiency that builds long-term client belief.
A Rising U.S. Dedication
The addition of froth manufacturing capabilities marks the newest milestone in Americanstar’s continued U.S. enlargement. The corporate has steadily grown its retail partnerships—together with latest expansions with Bel Furnishings and Mattress Agency Montana, in addition to a return to Las Vegas Market with the debut of its S-Class Hybrid Assortment.
With U.S. foam manufacturing now operational, Americanstar plans to develop its portfolio of proprietary consolation applied sciences throughout future collections, additional strengthening its aggressive place within the North American market.
“Each funding we make in our U.S. operations is pushed by the identical objective: serving to our retail companions succeed,” stated Nguyen. “Foam manufacturing is the muse of mattress innovation. By proudly owning that course of right here within the U.S., we’re guaranteeing that Americanstar can proceed to ship differentiated, high-margin merchandise that retailers have to thrive in as we speak’s market.”
