Domestic mattress industry: Fewer beds, bigger players, a battle for share

Sheila Long O’Mara// Executive Editor, Furniture Today//November 9, 2026

• At a Glance:
• Somnigroup acquires Mattress Firm and Leggett & Platt
• Imported mattress value drops over 40% after 2024 antidumping orders
• South Bay International controls Corsicana and Englander brands

HIGH POINT — The domestic mattress industry is getting smaller, but the stakes for the manufacturers still standing have never been higher.

With fewer mattresses being sold, consolidation reshaping the competitive landscape and low-priced imports capturing an increasingly significant share of the market, domestic producers are confronting a fundamental question: How to compete in a business that looks dramatically different than it did just five years ago?

For some, the answer is moving upmarket. Others are investing in vertical integration, doubling down on domestic production or finding new ways to reach consumers before they ever walk into a mattress store.

The numbers back them up. The U.S. mattress and foundation market shipped 13.2% fewer units in 2025, while its wholesale value fell a smaller 6.5%, to $9.25 billion, according to the International Sleep Products Assn. The value of imported mattresses has dropped by more than 40% in two years, according to U.S. International Trade Commission data, after a second wave of antidumping orders took effect in 2024.

Ownership is becoming more concentrated.

Somnigroup International, parent of Tempur-Pedic, Sealy and Stearns & Foster, acquired the nation’s largest mattress specialty retailer, Mattress Firm, in February 2025. In August 2026, it closed its purchase of its biggest component supplier, Leggett & Platt.

South Bay International now controls Corsicana and the Englander brand. And, Amazon sits as the country’s No. 2 bedding retailer, behind only Mattress Firm, by Furniture Today’s estimate.

“The industry as a whole is struggling,” said Gerry Borreggine, CEO of Therapedic Worldwide. “Some companies are doing great; some are struggling. There’s a lack of customers; there are good months, and there are bad months.”

Others were steadier. Mlily USA Chief Operating Officer Kyle Robertson called the domestic manufacturing business “stable,” and South Bay International CEO Toby Konetzny described a return to a normal, cyclical market after the pandemic’s “non-normal event.”

What no one disputed is that domestic producers are competing on new terms. Duties have helped at the border, but low-priced online imports, some of which fail federal flammability standards, set the price expectations for a large share of shoppers.

Makers are responding by moving upmarket, investing in vertical integration and trying to win consumers’ attention before they ever reach a store, including in AI search.

The total U.S. market for mattresses and stationary foundations was worth $9.25 billion at wholesale in 2025, down from $9.9 billion in 2024, according to ISPA’s Mattress Industry Trends Report. Those figures include imports and are based on a survey of U.S. manufacturers.

The gap between dollars and units is the defining feature of the category.

“Fewer units sold; higher average unit selling price on domestic mattresses,” said Laure Tokarz, president of Restonic Mattress, adding that the shoppers who left the domestic mix are largely at the bottom of the price ladder.

“The $399 and under consumer has turned to online retailers for their mattress,” she said. “The luxury customer continues to shop in stores and values that relationship.”

The decline was broad. Every U.S. region shipped fewer mattresses and foundations in 2025. The South remained the largest region, accounting for about 42% of the dollar value and 45% of the units of U.S.-produced goods.

South Bay’s Konetzny cautioned against measuring today’s market against the pandemic peak. He called that buying surge a “non-normal event” that gave the industry a selling season unlike any other. Now, he said, the business has returned to its normal pattern of cyclical sales events, with ups and downs.

Duties shrank imports’ dollars, not reach

The value of imported mattresses has fallen by 40.8% since 2023, according to USITC figures. Most of that drop came in 2024, the year the latest antidumping orders took effect.

The timing lines up with trade enforcement.

The U.S. Commerce Department issued antidumping orders on mattresses from Bosnia and Herzegovina, Bulgaria, Burma, Italy, the Philippines, Poland, Slovenia and Taiwan on July 11, 2024. Orders on India, Kosovo, Mexico and Spain followed on Sept. 10, 2024. Those cases came on top of an earlier antidumping order on mattresses from China, which the USITC reviewed in 2025. A companion countervailing duty case for Indonesia did not result in an order.

The 2024 import decline outpaced the overall market’s decline, which suggests the duties, not only weak demand, reshaped sourcing.

ISPA’s reading of 2025 is more cautious. Its report found that imported unit volume declined modestly while average values per unit fell more sharply, and that import activity grew in parts of Southeast Asia and Africa. The top 2025 sources by units were Indonesia, Vietnam and Mexico, out of 35 countries of origin, according to ISPA. Indonesia, the one country in the 2023 petitions that avoided duties, is now the largest source.

In other words, the duties shrank the dollars flowing to imports but not necessarily their unit footprint. Leggett & Platt estimates that imports grew from about 10% of U.S. mattress units a decade ago to more than 40%.

A note on comparison: USITC figures are customs values, which exclude duties, freight and importer markup, so they understate imports’ share of ISPA’s wholesale total.

Manufacturers said the duties have helped, but with limits.

“Tariffs are helpful for U.S. manufacturing,” said Robertson of Mlily USA. He said holes remain, with importers continuing to cross-ship product through other friendly countries to avoid tariffs or find lower rates. “We want a level playing field. It’s only as level as what the government can enforce.”

Robertson also tied the duties to a new problem. “Since the antidumping cases, we’ve seen an increase in fly-by-night brands pop up online. Some don’t meet the flammability standards U.S. manufacturers must adhere to. There is no product equity there.

“I don’t think imports are inherently bad, but we have seen some bad actors that don’t follow the rules,” he said.

Ongoing consolidation

The biggest structural change in domestic mattress manufacturing is not happening at the border. It is happening on the balance sheet.

“It’s an interesting time to be in this category right now with the ongoing consolidation,” Borreggine said. He traced the line from the Tempur-Pedic and Sealy merger to Mattress Firm to Somnigroup’s acquisition of Leggett & Platt, as well as other mergers throughout the industry.

Somnigroup completed its roughly $5.1 billion acquisition of Mattress Firm last year. Earlier this year, it completed its all-stock acquisition of Leggett & Platt, valued at about $2.3 billion at closing. Leggett will operate as a new reporting segment.

Within a week of closing, Somnigroup outlined plans that included branded innersprings, new component standards at Mattress Firm and bringing more of its spring production in-house.

Independent producers are already planning around that. “Because of Somnigroup’s acquisition of Leggett, we will see more importing of coils, or we’ll see manufacturers begin making their own coils so that they can control their own destiny,” said Tokarz.

At the value end of the market, South Bay has been the most active consolidator. It acquired the operating assets of Corsicana Mattress Co. a year ago, in a going-concern sale that preserved about 60% of Corsicana’s workforce.

It has since put the Englander brand under the same ownership. A South Bay affiliate acquired full ownership of Englander Sleep Products, and Corsicana will now make all U.S. Englander mattresses, replacing the brand’s network of independent regional licensees.

Konetzny said he expects ongoing consolidation.

“We do have some manufacturers with a noose around their necks right now,” he said. “If it gets tighter, they’ll sell. This is only the turn, and more mergers and acquisitions will occur. The pie remains the same size; it’s just that there are less of us splitting it.”

For a growing share of shoppers, buying a mattress has become one click. The price is right, and delivery is quick. Domestic makers say that convenience is teaching consumers to shop on price rather than performance and that some of what they buy is not legal to sell.

While Amazon does not disclose its mattress sales, Furniture Today estimated its 2024 bedding sales (mattresses, foundations and adjustable bases) at $3.1 billion, second behind Mattress Firm’s estimated $3.26 billion. The online retailer’s strength is at the low end where it dominates the $500-and-under mattress segment.

“Amazon takes a ton of units out of the marketplace, but the life expectancy of those mattresses is short,” said Richard Fleck, president of Paramount Sleep. “The disposable mentality is massive right now.”

The category, he said, is teaching consumers about price behavior, not performance.

Konetzny said economics are pushing the bottom of the market online. The cost to deliver a $199 mattress, given freight, fuel and labor, isn’t worth the sale for many traditional producers, he said.

Getting vertical

3Z Brands is among the competitors reshaping the market, and its investment is hard to miss.

The company recently completed a 280,000-square-foot expansion of its main plant in Glendale, Ariz., bringing the facility to 965,821 square feet of manufacturing space. The addition adds foam curing and storage capacity, as well as a molded pillow operation. 3Z pours its own foam and makes its own coils, and it operates plants in Glendale and Phoenix, Oklahoma City and Nashville, Tenn.

FXI is building on a broad U.S. footprint of its own. Its 424,000-square-foot factory in Auburn, Ind., makes its Molecule brand products and is one of about 20 domestic facilities the company operates.

“The flywheel is turning, as we continue to expand our footprint with key retailers,” said Mike Juoni, vice president of specialty bedding sales for FXI, who helps lead the Molecule brand.

Juoni sees two paths ahead for domestic production. “The big guys will continue doing what they do. The smaller companies have to get sharper and become more innovative in their product and the approach they take to the business.

“Despite the economic indicators pointing against us, retailers and manufacturers are finding ways to win.”

Paramount made its choice more than a decade ago. “We have chosen to play at higher price points,” Fleck said.

The sub-$1,000 business is online, he said, and that is not where the company wants to compete. “That’s a journey we started in 2014, and we’re sticking to our knitting at the better, premium price points.”

Mlily USA remains committed to its domestic footprint. “We’re committed to producing mattresses for the domestic market in the U.S.,” Robertson said.

The company has been shifting some production of mattresses, toppers and pillows to its Arizona facility since earlier this year. A major fire this summer at the Healthcare factory in South Carolina where some of its products were made accelerated that timeline.

“Made in the USA is a cornerstone of our strategy for the domestic market,” Robertson said. “The made in the USA tag only has cachet in the States right now. Historically, that had never been an issue, but the mindset shifted since the pandemic and the current isolationist approach.”

He also noted that politics weigh on consumer confidence, which remains tough as shoppers struggle with high gas and grocery prices.

DeRucci USA is taking a hybrid approach to sourcing for an AI-powered sleep system, said Guy Ray, CEO of DeRucci North America. Components come from Asia and the mattress is assembled in the U.S. Ray said that model works for a bed that will retail for $8,499 in queen and begin shipping in February.

Few expect a quick rebound. ISPA’s February 2026 outlook called for a near-flat market in 2026, after its earlier forecasts overestimated 2025.

Asked to look five years out, executives largely described the same landscape: fewer, larger manufacturers and retailers, with smaller players surviving by specializing.

Konetzny’s advice to the companies that remain was blunt. “If your big business plan is to wait for business to get better, you’re in trouble,” he said. “We are laser-focused on success across all our brands.

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