Custom-Size Mattress

We are here to help you when you need a custom-size mattress for:

RV mattresses
Antique and 3/4 beds
Boat beds
European-size mattresses
Floor cushions
Any special projects

You can choose from our collection of existing mattresses or futons and contact us with your specific requirements so we can prepare a price quote for you.

We can also make custom futon covers to add style and protection to your custom mattress.

Important things to consider for custom-size mattresses:

Production delays are longer than regular products for special orders (approx. 4-8 weeks)

Custom orders are non-refundable or exchangeable. It’s is your responsability to verify all measurements!

There are certain limitations due to the sizes of the raw materials:

Maximum total length: 80″ (203 cm)
We only make rectangular shapes (sorry, no heart-shaped mattresses 😉 )

5-year Warranty
Heat-regulating
Hypoallergenic
Made in Quebec
No Excess Packaging
Superior Quality Futon

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on purchases of $1000 or more

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Delivery Service Across Quebec & Canada

Orders, Delivery, Exchange Policy and Warranty

Mattress Made with Durable Components

Your custom-size mattress can be made with all these components :

High-density soy-based polyurethane foam
Natural latex
Eucalyptus fiber
Cotton fiber
Natural wool
Recycled polyester

For a wider range of eco-friendly and comfortable natural mattresses, explore our collection.

Futon d’or : Manufacturer Since 1981

Estimated Production Time : 0-4 weeks.

Our mattresses, futons and bolster cushions are hand-crafted using very few machinery and minimum packaging to reduce environmental impact.
All our products are inspected one by one for quality control.
The mattresses are standard North American sizes, select the needed size for more details.
We can make custom-size mattresses, futons and covers for all kind of usage : special size, floor cushions, recreational vehicule or other personalized project. Contact us with details about your project.

Special Orders Production Time : 4-6 weeks.

Component Description – Natural Wool

Our mattresses are made in a plush wool-quilted cover. Wool is the perfect fibre for bedding.

Regulates heat well, allowing the body to remain cool and dry.
Naturally hypoallergenic and anti-dust mites.
Wool is a natural fire-retardant.

Volume : 5.9 oz/square yard
Origin : New-Zealand
Quilting : Montreal
Cover confection : Gatineau

Unlike synthetic fibers, the wool fiber absorbs humidity and regulate the temperature to keep the body dry during the sleep. The wool can absorb to 30% of its own weight in humidity. This animal fibre is made to temperate the body temperature. It keeps the same function in our mattresses by absorbing the body humidity during the night. The body being dry, you can stay cool during summer and warm during the winter.

In addition to give an incredible comfort, the wool is added to the surface of our mattresses to respect the flammability requirements in Canada for the mattresses because it is naturally a fireproof material.
For more information about the flame retardants used in our futons and our mattresses

***The wool cover is not meant to be removed for washing.

Component Description – Eucalyptus Fiber

Eucalyptus fiber is used as the first layer under the mattress envelope. Already used in some textile products, this fibre has extraordinary temperature-regulating properties and we are proud to be among the firsts to use it in the materials that make up our mattresses.

Soft and comfortable, it is ideal when combined with latex or a firm foam to achieve a balance between firmness and comfort.
Regulates heat well, allowing the body to remain cool and dry.
Naturally hypoallergenic and anti-dust mites

Volume : 2″ (5 cm) before compression
Origin : Australia
Confection : Montreal

Eucalyptus fiber is a derived product of the eucalyptus tree pulp. The produced fiber is soft and perfectly convenient for mattress manufacturing because it is naturally hypoallergenic and anti-dust mites. Its great capacity to absorb humidity compared to its volume. Eucalyptus fiber has very high humidity absorption and breathing capacity which repels parasites like dust-mites who tend to infest humid environments. Also, its very fast drying ability considerably reduces the propagation of bacteria and moist, adding to the life span of the mattress, countering the development of bad smell in long-term.

Added to all these positive effects on our sleep, growing the eucalyptus plant is very easy, making it an eco-friendly material. The plants do not require any pesticides to survive and the tree reaches maturity very fast. Even better, eucalyptus forests almost need no water spraying to grow. Studies show that eucalyptus only needs 155 gallons of water/pound of produced fibre and half an acre of territory can produce about a ton of fibre. In comparison, organic Californian cotton drains 782 gallons of water/pound and needs 3.5 acres to get the same amount of produced fibre. Eucalyptus can also be planted on low quality lands without altering the fibre, giving access to good arable land necessary to grow high quality food.

The fiber goes through different steps for its manufacturing. The tree is first cut to wood chip and mixed with amine oxides, an organic, biodegradable and non-toxic solvent. The fiber is slowly dissolved, cellulose is extracted and its agglomeration forms the fabric. Then multiple cleaning and drying cycles finally allows creating a final product clean and soft to maximize quality and comfort.

99% of the solvent and water used in the process are recycled and used again, the loss being minimal is ideal for an eco-friendly product. Finally, the tree automatically reproduces its own new sprouts, considerably reducing the energy loss and carbon emanations form heavy machinery normally used by industries to replant trees.

Eucalyptus layers must be compressed and held by small tufts on the surface of the mattress. These tufts are made of a cotton string with a plastic end visible on the mattress, for a more handcrafted style.

Component Description – Cotton Fiber

Cotton fiber is used in our mattresses to add comfort by taking the body shape and absorb the humidity. A fresher sleeping surface will result in less movements and a better sleep.

The white cotton comes from the cotton flower that undergoes mechanical modifications. The jagged flowers are getting rid of their shell by passing through different vibration stages. Once the cotton is clean, a small percentage of polyester fibers are added to it following the futon flammability requirements in Canada. This cotton is naturally white and not chemically treated. The compound is distributed in layers of different sizes. We only use cotton in layers in the making of our futons. The cotton in layers is more resistant to compression and it allows to avoid any movement of the material inside the mattress.

Component Description – Natural Latex

Latex has most of the qualities one would require from a good mattress :

The elasticity of latex allows the mattress to adapt to the body shape and reduces uncomfortable pressure points.
A very durable component that loses little volume, ensuring that the mattress will keep its shape throughout the years.
Regulates temperature, allowing the body to remain cool and dry.
Naturally hypoallergenic.

Latex Type : natural Dunlop
Origin : Sri Lanka
Density : 5.3 lb/cubic foot for our firm latex, 4.7 lb/cubic foot for our soft latex
Firmness Measurement ILD : used in 6″ layers : firm (34-38), used in 2″ layers : soft (23-27)

Latex is a natural product made from the sap of the rubber tree (Hevea brasiliensis). This sap is harvested by making notches in the tree trunk. We use high-quality natural Dunlop latex. Although our latex is not certified organic, it is natural and not a synthetic blend. We believe this type of latex is the best in terms of quality at a reasonable price.

Component Description – High-Density Foam

High-density foam is used as a core in some mattresses and allows to make a durable mattress at a very competitive price.

No partner disturbance as movements are absorbed.
Firm with good back support.
Great lifespan.

Type of foam : Soy-based high-density polyurethane
Origin : Montreal
Density : 2.1 lb/cubic foot
Firmness Measurement : ILD/IFD firm 39-44

The foam we use is made specifically for bedding usage. It’s non-toxic and tested and certified by an independent organism, CertiPUR-US®, to make sure to follow the specific characteristic of performance, emission and environmental impacts.

Foam has been for many years an integral part of our futons and mattress. There is a variety of foam on the market which makes our products more diversified. While foam is a synthetic product, a percentage of soya oil, usually around 18%, can be added to the manufacturing process to obtain a similar product than all-synthetic foam.

It’s important to ask information about the density of the foam, as it will determine it’s durability. It is recommended to have a foam of superior density (2.1 lb/cubic foot) when you want to use the mattress in long term.

The high density foam make a very good core in a mattress due to its durability. However, if you sleep directly on the foam, it doesn’t breathe at all and the humidity makes it uncomfortable. It’s essential to add layers of natural fibers like wool and eucalyptus on the surface of the mattress so it breathes.

Component Description – Recycled Polyester Fiber

The recycled polyester is a fiber recently developed in collaboration with our suppliers to offer an economic alternative to the polyurethane foam. As its name implies, the layer is made of recycled polyester fibers which are jagged and put in layers. The final product is dense and more rigid than the lower quality of polyurethane foam; that’s why we use it in our more economic futons.

The Boreal Mattress Vision

Our Mattresses

We believe a mattress of quality is :
Healthy – Naturally hypoallergenic and without the addition of toxic flame retardants
Durable – Durable components to provide a true long-term value
Comfortable – Firm yet flexible support, and temperature regulating for a restorative sleep

Respect

Respect for our Customers
Transparent approach without any marketing gimmicks or false promotional offers
Detailed information on the materials used
Respect for the Environment
Environmentally friendly handcrafting process requiring minimal equipment
A $10 donation per mattress sold will be made to the organization Nature Conservancy Canada