Caravan and Campervan Mattress Manufacturing
Caravan and campervan beds are odd shapes. We build from a template or drawing using lightweight foam with washable covers.
Key points
- Template first. Trace the platform, including corner cuts, and note the available thickness.
- Weight and moisture. Lighter foam suits weight limits. Ventilated or perforated foam helps in damp conditions.
- Covers. Washable, zip-off covers suit travel use.
- How to send your template. Place paper over the platform, trace the outline, mark every corner cut and cut-out, note the thickness limit and photograph the template on the bed.
- Care in damp climates. Use a breathable underlay, lift cushions to air them, and wash covers regularly.
Template first
Trace the platform, including corner cuts, and note the available thickness.
Weight and moisture
Lighter foam suits weight limits. Ventilated or perforated foam helps in damp conditions.
Covers
Washable, zip-off covers suit travel use.
How to send your template
Place paper over the platform, trace the outline, mark every corner cut and cut-out, note the thickness limit and photograph the template on the bed. Send both. Fit a trial piece before a production batch if you are an operator with many vehicles.
Common caravan shapes
| Shape | Approach |
|---|---|
| Island double | Standard or cut corners |
| Rear corner bed | Template with angled cuts |
| Bunk | Thickness and rail limits |
| Convertible dinette | Multi-piece cushions |
Care in damp climates
Use a breathable underlay, lift cushions to air them, and wash covers regularly.
Fit and weight
Vehicles have weight limits, and a heavy mattress eats payload. Lighter foam keeps weight down, and ventilated or perforated foam helps in damp climates. Fit a trial piece in the vehicle before a fleet order.
Detailed guidance
Caravan beds are irregular and weight-limited. Make a template of the platform, with every corner and cut-out, and measure the height available. Choose lightweight foam and a cover that can be removed and washed. In damp climates, use ventilated foam or a spacer layer to allow airflow underneath.
Order a pilot piece and fit it in the vehicle before ordering many. Check that cushions can be lifted for storage access. Ask the maker about flammability evidence if the vehicle's use requires it. Document the final shape and keep the template for reorders. For fleets or manufacturers, agree tolerances and a sample approval step.
Worked example (illustrative figures)
A caravan maker has an island double with a 150 mm corner cut-out at each foot corner. A template shows the cut-outs and the maker orders a pilot of 10 mattresses to check fit before ordering 200. One small fix to a corner radius is made before volume.
Frequently asked questions
Can you make a bed with a cut-out?
Yes, from a template.
Where do I send my requirements?
Use the bulk and export request form or message Sleepwit on WhatsApp. We reply with questions and a written quote; prices, minimums and lead times are confirmed in the quote.
Need a quote for this? Sleepwit manufactures and exports to specification. Send your requirements and we reply in writing.
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