Before mass production transformed mattress making into an automated process, artisans spent days hand-tufting beds that would last generations. Michigan’s Harbor Springs Mattress Co., which debuted a Naples showroom in January, revives lost techniques with a contemporary focus on sustainability.
For the husband-wife duo behind the brand, Rory Karpathian and Dar Charlebois, the philosophy is simple: a mattress should be designed to be cherished, not discarded. Instead of offering vague durability promises, Harbor Springs guarantees each mattress for 25 years—a concrete commitment to longevity in an industry known for planned obsolescence.
Before launching the brand in 2004, Rory spent more than 30 years on the production floor of several large mattress manufacturers, managing as many as 400 workers who worked around the clock. He saw how companies moved to cheaper-quality products laden with synthetic foams and chemical adhesives that start to sag after a few years while silently polluting the bedroom with invisible chemical emissions. The couple was determined to do things differently.
Courtesy Harbor Springs Mattress Co./Michael Murphy
Photography by Ashlee Fleming
Photography by Ashlee Fleming
Courtesy Harbor Springs Mattress Co./Michael Murphy
Inside their Harbor Springs facility (they refuse to call it a factory), craftspeople and sewists compress innerspring coils for lasting support, then layer on plush natural materials. Everything is secured with multiple rounds of hand-tufting—guiding heavy-duty thread through each layer and anchoring it with hand-tied wool rosettes. The process—along with thoughtful extras like reinforced layering in the high-pressure lower-back area—ensures a responsive, pressure-relieving surface that contours to the body, provides even support, and maintains structural integrity by preventing shifting over time. “We set out to do better on purpose,” Dar says.
The Cozy, one of five styles they offer, takes it a step further with individual, handmade springs encased in fabric, resulting in less disturbance for couples—one partner’s midnight movements won’t disturb the other’s rest. For those looking for a more refined aesthetic, the Trillium elevates tufting with a removable topper that’s French-tufted, with invisible stitching creating a sleeker finish while maintaining durability.
The material selection reflects equal care. “There are sheep happily grazing in a Michigan farm whose fleece has been carded and milled into our wool batts,” Dar says. Natural wool provides temperature regulation and breathability without synthetic additives; organic cotton adds plush comfort; and natural latex delivers responsive support without petroleum-based materials. Everything drives toward better sleep mechanics, including a healthier nighttime environment free from toxic chemicals. “Each fiber is like a gift in what it offers—we are taking these gifts from Earth and making something that improves people’s well-being,” she adds. Nearly every component is biodegradable, and all excess cotton is recycled into the next model, helping offset landfill impact.
Courtesy Harbor Springs Mattress Co./Michael Murphy
Photography by Ashlee Fleming
Photography by Ashlee Fleming
Courtesy Harbor Springs Mattress Co./Michael Murphy
Prices range from about $1,800 (“It’s important to us that hardworking families also have an option,” Dar says) to $10,000 and include the hand-built steel box springs and white-glove delivery. “We could add silk or cashmere and charge thousands more, but we’ve taken a stand to be honest, transparent and to avoid unnecessary markups,” Dar says.
Located off Tamiami Trail, the new 1,500-square-foot showroom, designed by Michigan-based Chatham House Interiors, reflects the company’s ethos. Calming neutrals and ambient lighting create an inviting atmosphere. Dark wood side tables and floral arrangements complement the space, where each mattress is showcased on natural frames with linen headboards and dressed in organic cotton, bamboo, wool and mulberry silk linens. “Our stores are more like a serene art gallery, showcasing our artisan beds,” Dar says.
Their approach has earned the couple a robust Michigan following. Many of their Midwestern clients have second homes in Southwest Florida, making Naples a natural choice for the brand’s first expansion outside their home state. At the showroom, consultations are personalized, with staff taking time to understand individual sleep needs and preferences. Back in the Midwest facility, mattresses are built to order in small batches, never sitting in a warehouse before delivery. “I love to tell our customers that good music was playing in our Michigan workshop when their mattresses were made,” Dar says.