One partner. From brief to boxed. At any scale.
Who we are
Flex2000 is Europe's largest polyurethane foam manufacturing plant. Based in Ovar, Portugal, we produce complete Bed-in-a-Box solutions for D2C sleep brands, private label brands, and online mattress retailers across Europe and the world.
From all-foam constructions to hybrid pocket spring cores, we manage every step in-house: foam production, spring manufacturing, mattress assembly, laboratory testing and custom packaging. One partner. Full control. No bottlenecks.
Whether you are launching a new sleep brand or scaling an existing one, Flex2000 gives you the manufacturing capacity, technical expertise and supply chain reliability needed to grow without limits.
Why Flex2000 for your BIB Brand?
Europe's largest foam plant
Recognised at EUROPUR 2025 as the largest flexible polyurethane foam production facility in Europe. When your brand scales, we scale with you. Our capacity means you will never outgrow your manufacturer.
Complete in-house production
Foam, pocket springs, hybrid cores, assembly, testing, and packaging - all produced under one roof in Ovar, Portugal. No external suppliers, no hidden dependencies, no surprises on quality or lead time.
Built for D2C from the ground up
We understand the D2C model. Fast lead times, precise packaging specifications, unboxing experience, and roll-pack performance. Every solution we develop is optimised for online sales and direct-to-consumer logistics.
Made in Europe - shipped worldwide
European manufacturing means faster lead times for European brands, full compliance with EU standards, and the quality assurance your customers expect. We ship to markets across Europe, the UK, and globally.
6 specialised laboratories
Every Bed-in-a-Box model is developed and validated in our in-house Sleep Lab.
We test before you sell so your customers never have to test for you.
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Engineered to Perform. Tested to Endure.
Every Bed-in-a-Box solution developed at Flex2000 is rigorously validated in our in-house Sleep Lab before it reaches your customers. Our testing protocols meet the highest standards in the European sleep industry.
EN 1957 mattress testing
To evaluate durability, functional performance and long-term resilience.
Foam hardness (ILD) testing
To precisely measure the firmness of each foam layer used in the core.
Pressure mapping analysis
To assess pressure distribution and spinal alignment during sleep.
Zoning validation
To confirm the effectiveness and consistency of differentiated comfort zones.
Point elasticity measurement
To test localised responsiveness and adaptability to body weight.
Rebound and bounce testing
To analyse dynamic comfort and surface reactivity.
We share full test results with our clients. Transparency is part of the service.
What we offer
Bed-in-Box, toppers and pillows - complete OEM manufacturing in Europe.
Foam Cores
High-density polyurethane foams produced in-house, filler-free, and precisely calibrated for compression and recovery performance. Available in multiple firmness levels including conventional foams, HR foam, viscoelastic and others.
Pocket Springs Systems
Our Pockee pocket springs are engineered specifically for Bed-in-Box applications designed to resist deformation under roll-pack conditions and deliver consistent support over time. Available in standard and zoned configurations.
Hybrid Constructions
Combine the pressure relief of foam with the support and breathability of pocket springs. We co-develop hybrid cores tailored to your brand's comfort positioning, target market, and packaging constraints.
Custom Packaging & Branding
From box dimensions to printed artwork - we optimise CBM for logistics efficiency while creating an unboxing experience that reflects your brand. We work with your packaging team or develop from scratch wiht your guidance.
Private Label & OEM
We manufacture under your brand. Full white-label capability, from product development through to finished, branded, boxed product ready for your warehouse or fulfilment partner.
Toppers & Others
Beyond the core mattress, we also manufacture toppers and others - all produced in-house, engineered for roll-pack delivery, and ready to complete your brand's sleep catalogue. One manufacturer for your entire product range.
Through rigorous testing and co-development, we help you deliver Bed in a Box solutions that recover perfectly, perform consistently, and elevate your brand.
Let's create your next best-seller.
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