The Delta Core system maximizes the comfort and thickness of the mattress while minimizing weight and bulk. Our patent-pending coring process removes 40% of the initial volume of the polyurethane (PU) foam, giving a minimal packed weight and size.

This coring technique has the additional benefit of keeping the top and bottom surface of the PU intact. This ensures consistent warmth along the mattress, avoiding the vertical holes or frame-like gaps that have traditionally allowed warmth to leach downwards. The full foam surface provides a significantly improved bonding of the foam to the shell fabrics reducing the chance of delamination.

We have literally put a new twist on our very successful multi-function valve so it specifically addresses the inherent characteristic of self-inflating mats - that is, the problem of the foam trying to re-inflate as you're packing up. We've engineered the "one-way" inflation valve to be reversed and used to prevent the mat from drawing air back in. This allows you to roll the mat up as small as possible without fighting re-inflation as you go. This patent-pending valve design has the same slim profile, faster inflation than traditional screw valves, easy pressure fine tuning, and super fast deflation rate as our air mattresses and pillows.

Extrusion lamination is common in the medical and aeronautical industries, but Sea to Summit pioneered its use in outdoor products. Liquid Thermoplastic Urethane is applied to the face fabric through an extrusion head, where it bonds permanently. The common process for creating an airproof barrier, where a film is rolled onto a fabric, is prone to delamination. The result: Sea to Summit sleeping mats are more reliable and longer-lasting.