Hi gfandac,
There’s not a lot in the way of factory direct mattress manufacturers in the Washington, DC area (which I always find odd). There are however a number of options that provide better quality/value than the mainstream choices in the area. They are …
https://boulder.urbanmattress.com/ Vienna, Leesburg, VA. Retail direct outlet for their own house brand (Urban organics latex mattresses), along with a range of mattresses made by Sherwood, Suite Sleep, and VI Springs (ultra premium). Good people who have always been knowledgeable and open about their mattresses when I have talked with them. Some good value.
Information – American Foam Center Fairfax, VA., Hagerstown, MD. American Foam Center. They are a foam outlet but are also a local factory direct mattress manufacturer. I talked with Robert (who is the owner) and it’s clear that he “knows his stuff” about foam. He has been making mattresses for 50 years and is the kind of person that will give you accurate information. He also has a “showroom” (of sorts) where different materials and layers can be tested. He uses high quality materials like Latex (Dunlop and Talalay), high quality polyfoam up to 2.8 lbs (true HR foam) and memory foam from a quality American supplier. Some good quality and better value choices here compared to most mainstream choices and they would certainly be worth including in your research. Make sure you call first because Robert is the person there with the knowledge.
http://winndom.com/ Wholesale manufacturer who sells through local retail outlets. Their retail store finder has a list of stores that carry them (I would call the retailer to make sure it’s up to date). I have talked with them and I know they work closely with their retailers and provide good quality and value. In particular though … I would talk with Michelle at https://www.bedcraftersbymichelle.com/ in Williamsburg, VA who works very closely with them and is exceptionally knowledgeable and helpful about all their mattresses and mattress materials and construction in general and custom builds every mattress she sells. She is a great resource for Winndom regardless of which retailer you are dealing with.
https://www.yelp.ca/biz/ostrows-organic-mattress-superstore-bethesda-3 Bethseda, MD. They carry Savvy Rest component latex mattresses and OMI latex mattresses along with their own Ostrowpedic mattress as well.
https://www.roomandboard.com/ A retail direct outlet for Restwell. They sell a range of latex, memory foam, and other mattresses with fairly good value. Make sure you check the density of any polyfoam or memory foam in the mattress you are considering as some of them may be on the low side.
https://www.healthyback.com/ Retail outlet with stores in Bethesda, Rockville, MD and Vienna, Alexandria, Fairfax, VA. They carry a version of the Pure Latex Bliss mattress line that is a high quality Talalay latex mattress. They are great for testing latex and better quality and value than latex mattresses made by most major brands but higher priced than most local manufacturers. They have good knowledge and service and are very informative and helpful.
https://www.mattresstraditions.com/ Retailer in Falls Church. They carry quite a range of alternative brands (some of which are more costly and some of which are much less). Classic Sleep (a smaller national brand) and Winndom (a local wholesale manufacturer) may be better value here.
http://mattressfame.com/ Retailer in Rockville, MD. They carry several brands which may have better materials, quality, and value including Therapedic, Eclipse, and Eastman House, Englander, Pure latex bliss. They carry latex, latex hybrids and other options such as gel memory foam that may have some better value and are open to supplying the specs of their mattresses (to the degree that the information from their manufacturers allow it) so customers can make more meaningful comparisons.
https://www.abbafutons.com/ Gaithersburg, MD Foam and Upholstery shop that also sells some mattresses. Talked with him and he knows his foam. Carries polyfoam and memory foam but no latex. Sells Otis futons and basic foam mattresses.
http://www.themattressorganic.com/mattress.php Columbia, MD
savvyrestnaturalbedroom.com/ Vienna, VA and Rockville, MD. They carry Savvy Rest component latex mattresses which are a “choose your own layering” latex mattress that is available in both Dunlop and Talalay. They are in a higher budget range compared to other similar mattresses (several of the members here offer similar component latex mattresses for less) but they are a good place to test latex combinations and are knowledgeable about their materials so I would make some good value comparisons. The Savvy Rest company outlet itself may have the best choices available. They also carry a tufted wool mattress.
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https://www.creativeclassics.com/ Retailer in Alexandria, VA. They also carry Savvy Rest component latex mattresses.
Shop Affordable Home Furnishings & Home Goods - IKEA College Park, MD, Woobridge, VA. See post #3 here and the post it links to for some of the options here.
http://www.mtairymattress.com/ Mt Airy, MD Carries Restonic Gel (but but no latex) and Reverie latex mattresses. Said they would get foam specs from their factories for those that ask.
http://www.mattressstoremd.com/ Annapolis, Kent Island, MD. Has a Serta all latex mattress made to their specs (with an inch of poly on the bottom). Retonic latex hybrids (2" and 4" latex) and all latex (with 1.5" poly on top). Good people locally owned. Mostly mainstream major brand mattresses though.
The next closest factory direct manufacturers are both about 100 miles away in or near Richmond. They are …
Find an Original Mattress Factory Store Regional factory direct manufacturer which makes a range of mattresses including a two sided latex hybrid and two memory foam models with good quality/value. Be aware that they often have their latex mattresses set up on a box spring rather than a solid foundation which will change the feel of the mattress. You may wish to ask them to set it up on a solid foundation when testing if you plan to use them on a solid foundation or adjustable bed.
Most of the chain stores in the area I looked at also have little to nothing I would consider good value or even worth testing.
Since you are lighter … you would probably do well with a 2-3" talalay latex comfort layer in the range of 19 - 24 ILD over a medium firm to firm core (Talalay or Dunlop) in the range of 32 ILD or higher. As a lower cost alternative you could use a latex comfort layer over either an innerspring (probably a pocket coil or an offset coil) or a HD polyfoam core (1.8 lb density at a minimum but preferably higher).
Hope this helps in your search.
Phoenix