Customer Case Study

All Mesh Mattress Replacing Coconut Fiber

In 2013, we partnered with a baby brand on Tmall with strong mattress sales. Their coconut fiber mattresses faced issues in real use—odor during humid seasons, overly firm feel, and poor breathability. The client wanted a fully 3D mesh mattress to replace traditional materials and improve comfort and airflow.

All Mesh Mattress Replacing Coconut Fiber

Mefiss Solution

Our Solution

Step 1

Problem Diagnosis


Initial discussions focused on identifying real usage pain points. Coconut fiber cores tended to trap moisture during rainy seasons, leading to odor buildup. At the same time, the structure felt too firm and lacked airflow, making it less suitable for long-term infant sleep comfort.


Step 2

Layered Mesh Design


A full 3D spacer mesh structure was proposed. The top layer used 7mm T2D-53 mesh with DTY yarn, providing a smooth, skin-friendly surface. This allowed direct contact with baby skin while maintaining breathability, replacing the need for additional fabric layers.


Step 3

High Support Core


The internal support layer used three stacked layers of 20mm T2S-6Q high-strength mesh. This structure created stable rebound and long-lasting support through dense spacer yarns. The final mattress thickness reached about 7.5cm, balancing softness, support, and airflow.


Step 4

Glue-Free Upgrade


In the first three years, eco-friendly glue was used for lamination and edge sealing to ensure structural stability. With process improvements, we later achieved a glue-free construction by optimizing structural design and sewing methods, further enhancing safety and environmental performance.


Outcome

Results

The all-mesh mattress significantly improved breathability and comfort, reducing heat and moisture buildup. It gradually gained market acceptance and became an innovative alternative to traditional coconut fiber mattresses in the baby care sector.

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