Engineered Sleep
4th Generation Mattress Manufacturer - Modular Oversized Beds Since 1931
Engineered Sleep is a 4th generation, veteran-owned mattress manufacturer based in Greenville, South Carolina. The Orders family has been building mattresses since 1931 - that is over 90 years of manufacturing experience.
Unlike many bed-in-a-box brands that outsource production, Engineered Sleep is a real factory. They design, build, and ship from the same building. When you buy from them, you are buying directly from the people who make the mattress.
They are best known for their patented Duo modular mattress system, which solves two of the biggest problems with oversized beds: getting the mattress through your doorway, and letting couples choose different comfort feels on each side.
The Duo Epic Modular System
The Duo Epic is Engineered Sleep's flagship oversized mattress. The modular design addresses the most common question we hear: "How do you get a 9-foot mattress through a doorway?"
Here is how it works: The mattress ships in multiple manageable boxes that fit through standard doorways. You assemble everything in your bedroom - no special tools or professional installation required. The sections connect securely to create one seamless sleeping surface.
Key Features of the Duo Epic:
- ✓Modular shipping: Ships in boxes that fit through 32-inch doorways
- ✓Split comfort: Each side can have a different comfort feel - latex or memory foam, soft or firm
- ✓Durable support base: The foundation layer is built to last many years
- ✓Refresh program: Replace just the comfort layers when they wear out, not the whole mattress
- ✓10-year warranty: Coverage on materials and workmanship
The Refresh program is worth highlighting. Traditional mattresses are all-or-nothing - when the comfort layers wear out, you replace the whole thing. With the Duo Epic, you can swap out just the top comfort layers years down the road, extending the life of your investment significantly.
Available Sizes
Engineered Sleep offers more oversized sizes than most competitors. They carry five different large-format sizes:
| Size | Dimensions | Area | |
|---|---|---|---|
Wyoming King | 84" x 84" | 49 sq ft | Size guide |
Texas King | 80" x 98" | 54.4 sq ft | Size guide |
Alaskan King | 108" x 108" | 81 sq ft | Size guide |
Alberta King | 96" x 96" | 64 sq ft | - |
Perfect KingUnique | 80" x 98" | 54.4 sq ft | - |
About the Perfect King
The Perfect King is a unique offering from Engineered Sleep. It uses two queen-size platforms with a smooth edge design, creating an 80" x 98" sleeping surface. This size is sometimes called "double king" or "double California king" by other sellers. If you already have two queen foundations, the Perfect King might be an economical upgrade path.
See How They Build It
See how Engineered Sleep builds and ships their oversized mattresses:
Ready to buy? Use code BIGBED15 for 15% off your Engineered Sleep mattress.
Shop Engineered SleepPricing Overview
Engineered Sleep mattresses are positioned in the premium segment. They cost more than basic foam mattresses, but the pricing reflects several factors:
- •Modular design - solves delivery and customization challenges
- •Longevity - the support base lasts many years; only comfort layers need replacing
- •Refresh program - reduces long-term cost of ownership
- •US manufacturing - made in South Carolina, not imported
- •Split comfort - different feels on each side at no extra charge
For a detailed price comparison across all Alaskan King sellers, see our Alaskan King bed price guide.
Shipping & Policies
Shipping
- ✓Standard shipping: 4-7 days
- ✓Rush shipping available
- ✓Free shipping to contiguous US
- ✓Ships in multiple boxes for easy handling
Returns & Warranty
- ✓Comfort exchange program (layer swaps, not full returns)
- ✓10-year warranty on materials and workmanship
Why Engineered Sleep Stands Out
In a market full of bed-in-a-box startups, Engineered Sleep is the opposite: a real manufacturer with 90+ years of family heritage. They make the mattresses themselves, in their own factory, with their own team.
Their modular design solves the three biggest pain points of oversized beds:
Delivery
Ships in boxes that fit through standard doorways
Comfort
Different firmness on each side of the bed
Longevity
Replace comfort layers, not the whole mattress
They are also one of the few companies offering five different oversized sizes - including the Perfect King, which is hard to find elsewhere. If you want an oversized bed from a company that actually makes them, Engineered Sleep is one of the best options available.
Frequently Asked Questions
Does Engineered Sleep offer a sleep trial?
Engineered Sleep offers a comfort exchange program. You can swap out comfort layers if the firmness isn't right for you - it's a layer swap, not a full mattress return.
How does the modular mattress ship?
The Duo Epic mattress ships in multiple boxes that fit through standard doorways. You assemble the mattress in your bedroom by placing the modular sections together. No special tools are required.
Can each side of the bed have a different firmness?
Yes. The Duo Epic system allows you to choose different comfort layers for each side of the bed - one side can be latex while the other is memory foam, or you can choose different firmness levels.
What is the Refresh program?
The Refresh program lets you replace just the comfort layers of your mattress years down the road, rather than buying an entirely new mattress. The support base is built to last, so you only replace the top layers when they wear out.
Where are Engineered Sleep mattresses made?
Engineered Sleep mattresses are designed, built, and shipped from their factory in Greenville, South Carolina. They are a real manufacturer, not a dropshipper or reseller.
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