Mattress system and method

A method comprising:

• (a) determining one or more parameters specific to a first customer having a head, a torso, and lower extremities, comprising:
• determining one or more of the following:
• zonal weights of the first customer;
• sleep habits and patterns of the first customer;
• and
• objective body measurements of the first customer;
• and
• determining a first core cartridge profile, the first core cartridge profile being at least partially based on one or more of the following:
• the zonal weights of the first customer;
• the sleep habits of the first customer;
• and
• the objective body measurements of the first customer;
• (b) after determining the one or more parameters specific to a first customer, building a prototype mattress to specifications at least partially based on the one or more parameters specific to the first customer, the prototype mattress having a length direction, a width direction, and a height direction, wherein building the prototype mattress to specifications at least partially based on the one or more parameters specific to the first customer comprises:
• building a prototype core unit using at least the first core cartridge profile, comprising:
• providing a prototype core cover defining a first internal region, the prototype core cover comprising:
• first and second sides spaced in a parallel relation along the width direction;
• a third side perpendicular to each of the first and second sides and adapted to be proximate the first customer's head during use of the mattress;
• and
• a fourth side spaced from the third side in a parallel relation along the length direction, perpendicular to each of the first and second sides, and adapted to be proximate the first customer's lower extremities during use of the mattress;
• wherein the first internal region is defined by the first, second, third and fourth sides;
• selecting a first group of prototype core cartridges, each prototype core cartridge having a respective firmness characteristic generally specified by the first core cartridge profile;
• and
• disposing the first group of prototype core cartridges in the first internal region defined by the prototype core cover so that each prototype core cartridge is positioned next to at least one other prototype core cartridge and the prototype core cartridges are sequentially arranged along the length direction and between the third and fourth sides;
• (c) after building the prototype mattress, testing the prototype mattress to determine that the customer approves of the prototype mattress;
• and
• (d) after testing the prototype mattress to determine that the customer approves of the prototype mattress, building a custom mattress according to the specifications of the prototype mattress, the custom mattress comprising a first group of custom core cartridges having respective firmness characteristics that are respectively identical to the respective firmness characteristics of the first group of prototype core cartridges, wherein the custom mattress is different from the prototype mattress previously determined to be approved by the customer at step (c), and wherein the first group of custom core cartridges are all different from the first group of prototype core cartridges.