Hi jasonsmith,
I don’t keep a list of the specific mattresses or materials that each manufacturer makes because it would be impossible to keep up with but it would also depend on how you define “chemical free”.
Polyfoam and memory foam both are made with petrochemicals but many of them are certified for harmful substances or VOC’s through CertiPur. Most manufacturers make foam without flame retardants (although they also offer flame retardant foams as an option) because most mattresses use barrier fire retardant systems that don’t require flame retardant foam.
Synthetic fibers use chemicals in their production.
Synthetic fabrics use chemicals in their production.
Synthetic latex is made with petrochemicals but most latex is certified for harmful substances or VOC’s through OekoTex.
100% natural and organic latex can use up to about 5% chemicals (foaming agents, curing agents, soaps, gelling agents, accelerators, antioxidants, and others) to make the latex foam but it is also certified through OekoTex, Eco Institut or other similar certifications.
Solvent based glues contain chemicals but even latex based glues contain some chemicals.
The only chemical free fire barrier would be wool that didn’t use any chemicals because even the viscose/silica fire barriers use chemicals to make the viscose materials.
Most people would consider most of these these to be “safe” but if you wanted a mattress that didn’t have any chemicals of any kind regardless of whether any chemicals used were safe (and many are) then you would be limited to natural fibers (that didn’t use any chemicals in their production) and innersprings.
If safety is your concern rather than the actual use of chemicals of any kind then post #2 here can help you answer the question of “how safe is safe enough for me?” and which material certifications you are comfortable with.
Once you’ve decided which materials and fire retardant methods you are comfortable with then you could talk to local manufacturers or online manufacturers that made mattresses with these materials. If you don’t want any fire barriers or fire retardants at all … chemical or otherwise … then you could also ask them if they would make a mattress without any fire barriers or retardants with a prescription.
Phoenix