Standard fitted sheets cover the majority of beds, but a large and growing share of the market does not fit neatly into “single, double, queen or king”. Recreational vehicles, boats, hospital and care beds, adjustable beds, children’s cots, hotel beds with special toppers and mattresses sold in regional sizes all need fitted sheets made to measure. For brands and B2B buyers, these niches are attractive precisely because standard products do not serve them well.
This guide explains how a custom size fitted sheet manufacturer approaches non-standard dimensions: which markets need custom sizes, how to measure a mattress correctly, how the cutting pattern is calculated, which fabrics and elastic systems work best and what information to send with your order. For our full range of standard and custom options, visit the fitted sheet manufacturing page.
Who Needs Custom Size Fitted Sheets?
| Segment | Why standard sizes do not work | Typical buyers |
|---|---|---|
| Recreational vehicles (RV, campers) | Shorter lengths, cut corners, rounded ends | RV dealers, camping retailers |
| Boats and yachts | V-berths, tapered shapes, curved edges | Marine outfitters, yacht services |
| Hospitals and care homes | Narrow, long mattresses on adjustable frames | Healthcare suppliers, laundries |
| Adjustable and split beds | Mattresses split in halves or with split heads | Mattress brands, furniture retailers |
| Cots and cribs | Region-specific baby mattress sizes | Baby and nursery brands |
| Hotels and resorts | Custom mattresses, toppers, extra-long beds | Hotel chains, interior projects; see hotel fitted sheets |
| Export to multiple regions | US, UK and EU sizes differ | Retailers selling internationally |
| Premium mattress brands | Proprietary mattress dimensions and heights | D2C mattress companies |
Standard Reference Sizes
Before defining a custom size, it is useful to know how common sizes compare across regions.
| Size group | US / Canada | UK | EU |
|---|---|---|---|
| Single | Twin 99 × 191 cm; Twin XL 99 × 203 cm | Single 90 × 190 cm | 90 × 200 cm |
| Small double | Full 137 × 191 cm | Small double 120 × 190 cm | 120 × 200 cm |
| Double | – | Double 135 × 190 cm | 140 × 200 cm |
| Queen | Queen 152 × 203 cm | King 150 × 200 cm | 160 × 200 cm |
| King | King 193 × 203 cm; Cal King 183 × 213 cm | Super King 180 × 200 cm | 180 × 200 cm; 200 × 200 cm |
Even within one region, mattress makers vary by a few centimetres. That variation is one reason why brands often ask for custom sizes even in “standard” categories.
Examples of Common Custom and Niche Sizes
| Application | Typical mattress size (approx.) | Special features |
|---|---|---|
| Crib (US) | 71 × 132 cm (28 × 52 in) | Snug fit for safety, thin mattress |
| Cot (EU) | 60 × 120 cm or 70 × 140 cm | Snug fit, soft fabrics |
| RV Queen | 152 × 188 cm (60 × 74 in) | Shorter length than standard Queen |
| RV short queen / corner cut | Varies | One or two cut corners |
| Split King | 2 × Twin XL (99 × 203 cm each) | Two separate sheets or one sheet with split top |
| Hospital bed | Around 90 × 200–210 cm | Deep elastic, frequent high-temperature washing |
| Boat V-berth | Tapered, custom drawing | Pattern made from template |
| Extra-long single | 90 × 210 or 220 cm | For tall users, student housing |
Sizes above are typical examples. For custom orders, always work from the actual mattress measurements or a drawing.
How to Measure a Mattress for a Custom Fitted Sheet
Accurate measurements are the foundation of a good custom sheet. Ask your team or your customer to measure the actual mattress, not the bed frame.
| Measurement | How to take it | Tip |
|---|---|---|
| Width (A) | Across the top surface from edge to edge | Measure at the centre and both ends |
| Length (B) | From head to foot on the top surface | Measure along both sides |
| Height (C) | From the bottom edge to the top surface, including topper | Include pillow top and topper if the sheet covers them |
| Corner shape | Square, rounded or cut | Photograph or draw the corner |
| Shape outline | For tapered or curved mattresses | Make a paper template of the top surface |
For irregular shapes such as boat berths, a paper or plastic template traced directly from the mattress is the most reliable reference.
From Measurements to Cutting Pattern
A fitted sheet is essentially a rectangle with four square cut-outs at the corners. The corners are sewn together to form the “pocket”, and elastic is added along the edge.
| Pattern element | Calculation (simplified) |
|---|---|
| Flat panel width | Mattress width + 2 × (pocket depth + tuck-under allowance) + seam allowance |
| Flat panel length | Mattress length + 2 × (pocket depth + tuck-under allowance) + seam allowance |
| Corner cut-out | Square with side = pocket depth + tuck-under allowance |
| Tuck-under allowance | Usually 5–10 cm, so fabric wraps under the mattress |
| Shrinkage allowance | Added based on fabric lab test results |
Example: For a 160 × 200 cm mattress with 30 cm pocket depth and 7 cm tuck-under, the flat panel before shrinkage and seam allowances is approximately 160 + 2 × 37 = 234 cm wide and 200 + 2 × 37 = 274 cm long, with 37 × 37 cm corner cut-outs. The manufacturer then adds seam and shrinkage allowances according to the fabric used.
This is why fabric width matters: very large or deep-pocket sizes may require wide-width fabric to avoid joining seams.
Choosing Pocket Depth for Custom Orders
| Mattress height (incl. topper) | Recommended pocket depth |
|---|---|
| Up to 20 cm | 25 cm |
| 20–25 cm | 30 cm |
| 25–30 cm | 35 cm |
| 30–35 cm | 40 cm |
| 35–40 cm | 45 cm |
| Over 40 cm | 50 cm or more |
A pocket that is too deep leaves loose fabric that wrinkles; a pocket that is too shallow slips off the corners. For crib and cot sheets, a snug fit is especially important, so tolerances should be tight.
Fabric and Elastic Choices for Custom Sizes
| Application | Recommended fabric | Elastic system |
|---|---|---|
| RV and camper | Cotton jersey or cotton percale | All-around elastic for secure fit on moving vehicles |
| Boat berths | Cotton jersey (stretch helps with shapes) | All-around elastic, sometimes with extra corner straps |
| Hospital and care | Poly-cotton percale or cotton jersey | Strong all-around elastic resistant to hot washing |
| Crib and cot | 100% cotton jersey or percale | All-around elastic, snug fit |
| Adjustable beds | Cotton jersey or sateen with deep pocket | All-around elastic, extra depth at head end |
| Premium mattresses | Combed cotton sateen or percale | All-around elastic, deep pocket |
Jersey knit fabric is especially forgiving on non-standard shapes because it stretches. You can read more in our jersey fitted sheets wholesale guide.
MOQ and Pricing for Custom Sizes
Custom sizes do not necessarily require custom fabric. In many cases, the manufacturer can use the same fabric as a standard programme and only change the cutting pattern. This keeps costs and MOQ manageable.
| Scenario | Effect on cost and MOQ |
|---|---|
| Standard fabric, custom dimensions | Similar fabric MOQ; new pattern and possibly small set-up cost |
| Standard fabric, custom shape (cut corners, taper) | Additional pattern and sewing time |
| Wide or special fabric required | Fabric MOQ may increase |
| Very deep pocket (45 cm+) | More fabric per unit, higher unit price |
| Mixed custom sizes in one colour | Quantity can often be split across sizes |
Information to Include in a Custom Size Order
- Mattress width, length and height (including topper)
- Corner shape and any drawing or template
- Required pocket depth and tuck-under
- Fabric type, colour and weight
- Elastic type (all-around or corners)
- Quantity per size and colour
- Labelling and packaging needs, including size labels
- Target market and applicable labelling rules
Clear size labels are essential in custom programmes, because many sizes look similar when folded. Our private label fitted sheets guide covers labelling options in more detail.
Quality Control for Custom Fitted Sheets
For custom sizes, dimensional checks are even more important than for standard products.
| Check | Method |
|---|---|
| Flat dimensions | Measure length and width against the pattern specification |
| Pocket depth | Measure corner seam height |
| Fit test | Place sample on a mattress of the exact size |
| Shrinkage | Wash test (ISO 5077 / ISO 6330) and re-measure |
| Elastic recovery | Stretch and release test after washing |
| Seam strength | Visual and pull check at corners |
Common Mistakes in Custom Size Orders
| Mistake | Consequence | How to avoid it |
|---|---|---|
| Measuring the bed frame instead of the mattress | Sheet too large or too small | Always measure the mattress itself |
| Forgetting the topper | Pocket too shallow | Include topper height in the measurement |
| Ignoring corner shape | Sheet puckers or slips at cut corners | Send photos or a template of the corners |
| No size label | Similar sizes mixed up in stock | Use clear size labels or colour-coded tabs |
| Skipping the fit sample | Problems discovered after bulk production | Always approve a sample on the real mattress |
Custom Sizes as a Business Opportunity
For brands and retailers, custom sizes are more than a service; they can be a competitive advantage. Customers with non-standard mattresses often struggle to find sheets that fit, and they are willing to pay for a product that solves the problem.
| Opportunity | Why it works |
|---|---|
| Niche online stores | Lower competition for specific size searches, e.g. RV or cot sheets |
| Mattress brand bundles | Sheets sold together with a proprietary mattress size |
| Hotel and project supply | Extra-long or topper-ready sizes for specific beds |
| Repeat customers | Once a customer finds a sheet that fits, they reorder |
Starting with one or two niche sizes in core colours allows you to test demand before expanding.
Frequently Asked Questions
Can you produce custom sizes in small quantities? Custom dimensions often use the same fabric as standard sizes, so quantities can be flexible. The final MOQ depends on the fabric and colour selected.
Can I mix standard and custom sizes in one order? Yes. Many buyers combine standard sizes with a few special sizes in the same fabric and colour, which helps meet fabric MOQ.
Do custom sheets take longer to produce? A new size needs a new pattern and a fit sample, which adds a short step at the beginning. After approval, production time is similar to standard sizes.
Can you match the fabric of my existing sheets? Send a physical sample of your current fabric. The manufacturer can analyse its construction and propose the closest match.
What if the mattress shape is irregular? For tapered or curved mattresses, such as boat berths, a full-size template traced from the mattress is the best basis for the pattern.
Custom sizes turn fitted sheets from a commodity into a solution. Whether you supply RV owners, boat builders, hospitals, nurseries or premium mattress customers, a custom size fitted sheet manufacturer can translate exact measurements into a sheet that fits properly and lasts.
Jante Textile has produced bed linen for international buyers from Denizli since 1986 and works from your measurements, templates and specifications. See our fitted sheet options or send us your mattress dimensions to receive an offer.