Meet&CoWACO, Texas — Americanstar Mattress has begun in-house foam production at its manufacturing facility here, marking the first time the company has poured foam in the United States. The strategic investment is designed to accelerate product innovation, shorten lead times, and equip retail partners with proprietary comfort technologies that support margin protection.
Company executives stated that the move strengthens Americanstar’s vertical integration strategy and enhances its capacity to develop materials specifically tailored to U.S. consumer preferences.
Tony Nguyen, Chief Operating Officer for Americanstar U.S., noted that while the company has more than 20 years of experience pouring foam internationally, bringing that expertise stateside represents a significant advancement. He explained that manufacturing foam in-house at the Waco facility allows for faster innovation, tighter quality control, and the creation of comfort technologies purpose-built for the U.S. market—giving retail partners a competitive edge.
Americanstar Group has operated as a vertically integrated mattress manufacturer for over 25 years, serving retailers and distributors across more than 30 countries. Foam production has long been central to its global model, with proprietary formulations developed overseas. The Waco operation now brings formulation, testing, and production closer to its domestic retail base.
The company highlighted its proprietary SilkFoam technology as a direct result of its in-house foam expertise. This responsive material, with a silk-like texture, delivers pressure relief and contouring performance distinct from traditional memory foam and latex. SilkFoam is now featured across multiple Americanstar collections, including the Presidential Hybrid, Cleopatra, and S-Class Hybrid lines.
Beyond product innovation, the company cited reduced supply chain complexity, shorter development timelines, and improved cost efficiencies as key benefits of domestic foam production. Vertical integration from foam pouring to finished mattress assembly is expected to strengthen wholesale pricing and provide retail partners with exclusive, high-margin offerings.
The investment aligns with Americanstar’s broader U.S. expansion strategy, which includes recent retail partnerships with Bel Furniture and Mattress Firm Montana, as well as a return to the Las Vegas Market with its S-Class Hybrid collection.
Nguyen emphasized that every U.S. investment is driven by a singular goal: supporting retail partner success. By owning the foam production process domestically, Americanstar is positioned to continue delivering differentiated products that help retailers thrive in today’s competitive market.
