Hi Nancycs,
There are several factory direct manufacturers within reasonable driving distance of you that I know of but http://myrestassuredmattress.com/ is the only one that is local. I haven’t talked with them but I have developed a good sense of the type of manufacturer that provides good quality and value and they definitely fit the profile. They appear to offer innerspring and memory foam options but I don’t see anything about latex on their website although it wouldn’t surprise me if they offered this as well. I would certainly pay them a visit as it is very likely that the quality and value here is better than the other outlets in your area.
ADDED: I have since had several lengthy conversations with Chuck and there is no doubt that he is “mattress people” and makes high quality and value mattresses. They are also known and respected by other manufacturers I have talked with. I would make them my first stop if I was in the Rochester area.
The others are in the Minneapolis/St Paul area. They are …
http://www.restwellmattress.com/locations.asp Local factory direct manufacturer who makes a range of innerspring, memory foam, and latex mattresses that are transparent about their materials and have good value.
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Find an Original Mattress Factory Store Regional factory direct manufacturer that makes a wide range of mattresses including innerspring, memory foam (just introduced) and latex that also use good quality materials and have good value. One of the larger factory direct manufacturers in the country.
Natural Mattress Co. A local mom and pop supplier in Crystal, MN that supplies mattress components including 5 different firmness levels of 3" Dunlop layers, wool batting, and mattress covers (including wool quilted) that you can put together at home. The work from their home where you can go to test different layer combinations. Since these are components only, you can build a mattress without a fire barrier.
There is a larger list in post #2 here that includes these and some additional local retailers.
Unfortunately, it is not uncommon at all for a 6 year old major brand mattress to cause discomfort as the foam softens and begins to break down creating alignment issues over the course of the night. This is one of the reasons I like more local or regional factory direct manufacturers because they use higher quality materials and better construction methods which results in much longer lasting mattresses with better value.
One other advantage of most local manufacturers is that they will make side to side “split” construction mattresses where each side is built to the needs and preferences of different people. This can be really valuable as instead of having to compromise on what is best for both of you … you can each choose a construction that is better suited to your individual needs and preferences.
Side and stomach sleeping is a particularly challenging combination because stomach sleepers typically need a firmer and thinner comfort layer with a firmer support layer underneath it to prevent the pelvic area from sinking in too far leading to a swayback position which can often cause back issues. The “goal” here is to use the thinnest and firmest possible comfort layers on the top of the mattress which alleviates pressure issues on your side so that you are in better alignment when on your stomach. It’s important though not to go too thin or too firm (for the top layers) because that can lead to pressure issues when you sleep on your side so the “thinnest and firmest that does the job” is usually the best.
Memory foam is a non supportive foam because it will allow you to sink in more than other foams … particularly with your heavier areas. It is all “soft” foam even though it often feels firm when you press it quickly or when it is cooler. If you do choose to go with memory foam … I would make sure that it was not too thick because it will allow your pelvic area to sink in deeper than other foams. High quality polyfoam (HR grade) or high quality latex have what is called a higher support factor (they get firmer faster as you sink deeper into the foam) and are much better at adapting to different sleeping positions than memory foam however they have a much different feel. They are also cooler foams … particularly latex … than memory foams (although the gel memory foam is cooler than other types of memory foam).
Because your husband is heavier … he will likely need a firmer comfort layer than you (firmer foam feels softer to heavier people than it does to lighter people) and perhaps a little thicker as well to accommodate his larger size and because he probably spends more time on his side than you do.
Most local manufacturers though are quite expert at “fitting” a mattress to your weight and body shape, sleeping positions, and preferences and it is certainly more accurate to do this in person with someone who is good at this than to make more “typical” suggestions based on averages which may not be suitable for your own unique needs.
I have no doubt that with the 3 choices you have within a reasonable distance (or even with the one that is local), it is unlikely that you will have to spend time at any of the mass marketing outlets or even buy a mattress from an online outlet such as Sams Club which is great because of the return policy but not so great in terms of actually knowing whether a particular mattress will be suitable for your needs and preferences and can’t be “customized” in the same way or offer a side to side split construction if it is needed.
I’d certainly be interested in hearing about your experience with Rest Assured if you do pay them a visit.
Phoenix