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Research and Development

The importance of R&D

We are proud to have a unique and diverse team in R&D with extensive technical knowledge and industry experience. Hailing from varied disciplines, the team includes designers, engineers, scientists, project managers, mechanical specialists, upholsterers and more.

From ensuring that the comfort of each mattress is as exceptional as possible, to testing the sturdiness of the mattress edge or the durability of the mattress itself, Sealy’s Research and Development team strive for nothing less than perfection.

With the only accredited mattress test lab in the country, we take R&D seriously. We are constantly working on developing better beds to help people all over the world get a better night’s sleep.

How We Test

Sealy Research and Development

The Importance of R&D

We are proud to have a unique and diverse team in R&D with extensive technical knowledge and industry experience. Hailing from varied disciplines, the team includes designers, engineers, scientists, project managers, mechanical specialists, upholsterers and more.

From ensuring that the comfort of each mattress is as exceptional as possible, to testing the sturdiness of the mattress edge or the durability of the mattress itself, Sealy’s Research and Development team strive for nothing less than perfection.

With the only accredited mattress test lab in the country, we take R&D seriously. We are constantly working on developing better beds to help people all over the world get a better night’s sleep.

Example of how Sealy tests the mattresses
See How We Test Our Mattress
Example of how Sealy tests the mattresses

What do we measure?

Comfort Layers

Your Sealy mattress is designed to cushion your pressure points and minimise any impact on your body. We use this research to develop mattresses with optimal comfort layers for deep, refreshing sleep.

Sealy Pressure Mapping Test

This test reveals how well our mattress cushions your body, ensuring you’re not just supported, but truly comfortable.

Sealy Cornell test

To ensure long-lasting durability, this test proves our mattress can handle repeated wear without losing its comfort, height or shape.

Sealy Partner disturbance test

We measure how effectively the mattress reduces motion, helping you sleep undisturbed—even when your partner shifts or turns.

What do we measure?

Support systems

We test our support technology to ensure it promotes correct spinal alignment. In addition, we ensure our comfort layers, construction methods and designs work in harmony with our coils to offer correct support.

Sealy Rollator test

To ensure lasting comfort and structure, this test confirms our mattress can withstand years of movement without losing its shape or support.

Sealy Spinal alignment manikins

This test ensures our mattress promotes proper spinal alignment, supporting your body in a healthy, natural sleeping posture.

Sealy Robot seated test

Designed to test edge durability and surface resilience, this process ensures our mattress remains supportive and comfortable through daily use.

What do we measure?

Quality and durability

We conduct testing on every component and material that goes into a mattress, including panel fabrics, handles, comfort layers, edge supports and springs.

Sealy Foam firmness test

Our foam is carefully assessed to ensure consistent comfort and durability, with no unwanted additives that could affect long-term performance.

Sealy Tumble pilling test

We test our fabrics to ensure they resist pilling, tearing, and surface wear—so your mattress stays smooth, strong, and high-quality for years to come.

Sealy Pilling test

We check that every panel fabric can withstand repeated friction and maintain a smooth, pristine finish throughout the mattress’s lifespan.

Our research and development lab

Where design is tested and perfected

Sealy has conducted ongoing research and testing of new components, materials and construction methods with the National Association of Testing Authorities (NATA) in Australia. This ensures that every Sealy mattress provides the comfort and support you need for a restful night’s sleep.

Sealy Raw Material Testing for consistency

Raw Material Testing

All materials are tested to meet national and Sealy’s internal standards for strength, consistency, and performance.

Sealy Posturepedic mattress research and development

Finished Mattress Testing

Finished mattresses are evaluated for comfort, support, and long-term durability—contributing to our industry-low return rate.

Sealy Research and Development on a new posturepedic mattress

New Product Development

Every new design undergoes thorough testing to meet real customer needs and live up to Sealy’s promise of quality sleep.

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National Association of Testing Authorities (NATA) accredited Research and Development Lab

Our research and development lab

Where design is tested and perfected

Sealy has conducted ongoing research and testing of new components, materials and construction methods with the National Association of Testing Authorities (NATA) in Australia. This ensures that every Sealy mattress provides the comfort and support you need for a restful night’s sleep.

National Association of Testing Authorities (NATA) accredited Research and Development Lab
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Inside The Adjustable

Massage

Dual Massage Function

Experience the ultimate relaxation with a built-in massage feature.

Under-bed LED Lights

Navigate the room at night without disturbing your partner’s rest.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

Inside The Adjustable

Functions

Smart Charging Point

Integrated USB and Type-C charging ports, make it easy to keep your devices charged and within reach.

Under-bed LED Lights

Navigate the room at night without disturbing your partner’s rest.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

Inside The Adjustable

Adjustability

Comfort at All Angles

Effortlessly adjust the position to suit your needs, from reducing snoring to relieving pressure points, promoting better circulation, and supporting overall relaxation.

FlexiCased™

A unique articulating perimeter maximises the sleep surface and reinforces stability in adjustable mattress models.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Inside The Adjustable

Support

AlignSUPPORT®

The latest state-of-the-art technology, AlignSUPPORT® system is designed to sense your weight and responds with the support needed to help maintain your body’s natural alignment.  

– 6% improvement in deep down support.
– 75% reduction in lateral movement.
– 18% reduction in motion transfer.

FlexiCased™

A unique articulating perimeter maximises the sleep surface and reinforces stability in adjustable mattress models.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

Inside The Adjustable

Comfort

ComfortCore®

High performance comfort layer quickly confirms your body shape for enhanced pressure relief in any sleep position.

SmarTex™

Intelligent fabric cools and regulates your sleep climate while maintaining a clean & hygienic surface.

Inside The Advantage

Comfort

Comfort Layers

A blend of high quality fibres and ultra soft foam offers a great level of conformance to the back and hip area.

LiftRight ® Handles

Intelligently designed handles are placed to make moving your mattress easier.

Inside The Advantage

Support

PostureTech®

The patented Titanium coils provides vital support for your back, senses and responds with correct level of support while you sleep.

EdgeGuard®

A firm polyurethane insert provides an average of 10% more sleeping surface and a firm seating edge of the mattress.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

INSIDE THE ELEVATE

Comfort

ComfortCore® Premium

The concentrated layer of quality foam conforms to the lower part of the back, designed to relieve pressure where it’s needed most.

SmarTex® with IceTouch™

Exclusive fabrics that wicks away moisture and helps to regulate the sleep surface temperature is needed throughout the night.

INSIDE THE ELEVATE

Support

AlignSUPPORT®

The latest state-of-the-art technology, AlignSUPPORT® system is designed to sense your weight and responds with the support needed to help maintain your body’s natural alignment.  

  • 6% improvement in deep down support.
  • 75% reduction in lateral movement.
  • 18% reduction in motion transfer.

UniCased® XT

A broad profile edge support system that surrounds and locks into the support system for greater stability and edge-to-edge comfort for an uninterrupted sleep.

INSIDE THE PosturePremier

Support

PostureTech®

The patented Titanium coils provides vital support for your back, senses and responds with correct level of support while you sleep.

EdgeGuard®

A firm polyurethane insert provides an average of 10% more sleeping surface and a firm seating edge of the mattress.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

Inside The PosturePremier

Comfort

Comfort Layers

A blend of high quality fibres and ultra soft foam offers a great level of conformance to the back and hip area.

LiftRight ® Handles

Intelligently designed handles are placed to make moving your mattress easier.

INSIDE THE PostureLux

Comfort

ComfortCore®

A high density foam layer to mould and conform to the lower part of the back, where it’s needed most.

LiftRight ® Handles

Intelligently designed handles are placed to make moving your mattress easier.

INSIDE THE PostureLux

Support

PostureTech®

Designed with SensoryArm™ to detect the shape, weight and movement of your body while you sleep, then responds to provide correct spinal alignment.

Unikey®

Full perimeter edge support system that adds stability, provides a firm seating edge and extends the sleep surface for a better night’s sleep.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

INSIDE THE Enhance | Aspire

Comfort

ComfortCore® Premium

Step up to ComfortCore® Premium where memory foam offers a greater level of conformance to the lower part of the back, where it’s needed most.

SmarTex® with Ice-Touch™

A smart textile fabric treatment that responds only when it’s needed a disperse heat and moisture so you can sleep more comfortably.

INSIDE THE Enhance | Aspire

Support

SRx®

Backed by world-leading orthopaedic research, the SRxII® coil support system delivers initial conforming, support and deep down support for a more restful, recuperative sleep.

UniCased® XT

Reinforced edge support system wraps around the bed perimeter for exceptional stability and a faller sleep surface even at the outermost points. 

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

INSIDE THE PALATIAL CREST

Comfort

ComfortCore® Plus

The centre third of the mattress is enhanced with the ComfortCore® Plus, a layer of gel-infused visco elastic to provide superior conformance and alignment to the lower back, where it’s needed most.

SmarTex® with Ice-Touch™

Fabrics that cools and regulates your sleep climate while maintaining a clean and hygienic sleep surface.

INSIDE THE PALATIAL CREST

Support

RestSUPPORT™

Responsive support technology coil system uniquely designed for three stages of support:-

  • 1st Stage —  the micro-conforming SynerFlex surface cradles every part of the body.
  • 2nd Stage — The upgraded Align Head design senses the body’s weight and responds with initial conforming support.
  • 3rd Stage — Provides an extra deep-down support the body needs.

UniCased® XT

Our innovative edge support encapsulates the spring system to enhance stability and help to reduce motion transfer.

DuraFlex® Foundation

Made with Titanium alloy steel modules disperse shocks and stresses on the mattress to ensure long-lasting, performance and extended comfort life.

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

INSIDE THE EXQUISITE

Support

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

RestSUPPORT™Coil Technology

RestSUPPORT™

Backed by scientific research, the intuitive support system delivers 17% more pressure relief while maintaining your body’s natural alignment. Uniquely designed for three stages of support:-

  • 1st Stage —  the micro-conforming SynerFlex surface cradles every part of the body.
  • 2nd Stage — The upgraded Align Head design senses the body’s weight and responds with initial conforming support.
  • 3rd Stage — The Posturepedic® innercore is designed to sense the load applied and provide the orthopaedically correct response.

UniCased® XT

Sealy’s most innovative edge support system, encases and locks into the support system for exceptional edge-to-edge stability, designed to provide undisturbed sleep.

INSIDE THE EXQUISITE

Comfort

Backed by scientific research, this intuitive three-stage coil system provides the balance you need for a deeper, more luxurious rest. The Synerflex surface reacts to your contours, allowing maximum pressure relief, while the inner coil senses your weight and responds. The core of the coil provides deep down support to help maintain your body’s natural alignment and assist in ensuring a deep, restorative sleep.

ComfortCore® Plus layer

ComfortCore® Plus

A unique centre third layer to provide superior conformance and alignment to the lower back, where it’s needed most.

SmarTex® fabric

SmarTex® with IceTouch™

Fabrics that cools and regulates your sleep climate while maintaining a clean and hygienic sleep surface.