The Client

Over the years, Utah Contract Sewing has supported Antarctic Logistics with design development, material sourcing, and specialty production for a variety of custom products. These projects have included tent components, windscreens, flags, and other equipment developed for the unique demands of Antarctic operations.

The Project

This project focused on the latest production run of fitted covers for Therm-a-Rest NeoAir mattresses, completed in 2025.

The mattresses provide a comfortable sleeping surface, but suitable aftermarket fitted sheets were not available. Although each mattress included an original removable cover, the material attracted lint and dirt easily and was not ideal for continued operational use.

Antarctic Logistics needed a fitted cover that was more functional, comfortable, washable, and durable.

Our Approach

UCS designed and developed a form-fitting cover specifically for the mattress. Our team created the patterns, sourced the fabrics and components, and completed all cutting and sewing in our Salt Lake City shop.

The cover was designed to fit securely around the mattress while remaining easy to remove for washing and repeated use.

Materials and Construction

Each fitted cover is made from comfortable and durable 4-ply nylon Taslan, along with the necessary narrow goods and closure buckles.

The materials and construction were selected to withstand repeated use, cleaning, transportation, and the demanding conditions associated with Antarctic operations.

The Result

Utah Contract Sewing has produced hundreds of these fitted mattress covers in our Salt Lake City shop over multiple production runs.

Additional covers have been produced as operational needs have grown and older covers have been retired after long and demanding service at the South Pole.