The Bonnell spring system remains one of the most widely used support structures in mattresses and sofas—even in 2025. Despite the rise of pocket springs, foam hybrids, and advanced ergonomic materials, countless factories around the world continue choosing Bonnell springs for one simple reason:
✔ Low production cost
✔ High durability
✔ Stable performance
✔ Suitable for mass production
This article explains what a Bonnell spring system is, why it is still popular, and how it is manufactured using modern bonnell spring machine, including both semi-automatic and fully automatic production lines.
In the mattress manufacturing industry, the term Bonnell Spring System is also known as a:
Bonnell Spring Structure
Bonnell Spring Unit
Bonnell Spring Core
It is a support system made by assembling multiple hourglass-shaped steel springs into a complete spring unit. The springs are connected using spiral/helical wires, and the outer frame is reinforced by border rods, forming a stable and durable structure.
By using steel wires of different diameters, manufacturers can produce Bonnell spring units in various firmness levels—from softer to firmer—simply by adjusting the coil diameter, wire gauge, and number of turns.
Typical Bonnell springs contain 4–7 turns, depending on the mattress height and supporting requirements.
Even with the rapid growth of new mattress technologies, Bonnell units remain essential in many factories because:
Wire consumption is low, and production machinery is relatively affordable.
The hourglass structure distributes pressure evenly and can withstand years of use.
The system is perfect for factories producing high volumes for hotels, dormitories, emerging markets, and sofa manufacturers.
The interconnected design gives a firmer, more stable feel—ideal for customers who prefer a harder mattress.
For these reasons, Bonnell systems are still widely used in mattress factories, sofa manufacturers, and bulk OEM production lines.
Bonnell units can be manufactured through two main production methods:
① Semi-automatic production
② Fully automatic integrated production
Below is the complete explanation.
This method uses two separate machines:
This machine forms the individual hourglass springs.
It performs:
In the next step, workers bring the coils to the assembly machine.
The machine then:
Once formed, the Bonnell springs move forward along the output chute instead of falling down. Workers then collect them and feed them into the assembly machine. Check the video below to see how it works step-by-step.
For factories focusing on high efficiency, low labor cost, and consistent quality, a fully automatic line is the best solution.
This advanced machine integrates all functions into one continuous workflow:
The operator only needs to:
Then the machine runs automatically.
This type of automatic line is especially suitable for producing double-cone Bonnell spring units used in both mattresses and sofas.
Many people confuse the two systems, so here is a clear comparison.
Pocket Spring System
Bonnell Spring System
Pocket Springs:
Press one corner → only the springs under your hand compress.
Other springs remain independent.
→ Higher comfort, less motion transfer.
Bonnell Springs:
Press one corner → springs across a large area move together.
→ Firmer feel, stronger motion transfer.
For readers interested in how pocket spring systems are made, you can visit our Pocket Spring Machines page.
The Bonnell spring system is one of the most reliable and cost-effective spring structures in the mattress and sofa industry. Its combination of durability, firmness, and production efficiency ensures that it will continue playing an important role—especially in large-scale manufacturing.
Whether produced through semi-automatic or fully automatic equipment, modern technology has made Bonnell spring production faster, more precise, and more stable than ever.
KIMKOO offer multiple types of pocket spring assembly machines — some can connect with 2 coilers, and others up to 3. Freely combine with pocket spring coiling machines of different speeds. Easily set up a 1-to-1, 1-to-2, or 1-to-3 production line to match your capacity. Customize your setup today!
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