Flex-Head® Designs: The History and Benefits of Individual Comfort


Less than 25 years ago, the first Split Top or Flex-Head design was dismissed as a “dumb idea that would never sell.” Today, it is one of the most prominently featured styles in the industry.

One of the most fundamental challenges the bedding industry is that most Americans share their bed, and most couples don’t agree on what feels best.

Deciding on both firmness and elevation can be especially difficult for couples. This challenge was personal for Dan Wall Sr., and he was determined to find a solution.

In 1997, Wall made his first impact on the industry when he sold 60 adjustable firmness mattresses at one Florida State Fair. He had rented the booth and secured his supplier with a personal guarantee because the concept of was so unproven. Wall’s success at the fair was driven by his product demonstration that showed just how easy it was to adjust the mattress to meet a sleeper’s changing needs, and his demonstration was born from his conviction that individual comfort is essential.

This conviction came from personal experience. Wall and his wife were determined not to sleep in separate beds, despite having very different preferences. Instead, they purchased a king adjustable firmness mattress directly from Bob Walker. Almost immediately, they noticed significant improvements in their sleep quality. Adjustable firmness helped relieve pressure on their shoulders and hips, and they both enjoyed their ideal comfort. By adding two twin XL adjustable bases, they could elevate each side of the king mattress slightly differently—and for a time, it was the perfect solution.

 

In 2001, Mrs. Wall developed a medical condition that required significant head elevation. One night, she raised her side of the bed so high that her husband was nearly dumped onto the floor. That moment sparked an idea. A full split mattress was an obvious solution, but Wall was well aware of common complaints—mattresses sliding apart, not being able to snuggle, and inconvenience when “visiting.” The insight was clear: independent head elevation without fully separating the mattress to complement the core feature of adjustable firmness on each side.

Wall approached his supplier to develop a mattress with only the head section split. After an initial rejection, a fortunate introduction helped make the prototype possible. Wall committed to purchase all the custom covers, and the DW660ST—”the Dan Wall 660 Split Top”—was born.

The benefits of the design were immediately apparent, both at home and on the sales floor. Excited by the success, Wall pursued intellectual property protection but was ultimately advised against filing a patent, in part due to the potential costs of enforcement. Despite that setback, he launched and marketed the product successfully, with his exclusive DW660ST model, building strong consumer demand.

In 2013, Wall was forced to look for a new supplier to ensure that he could continue to deliver on his mission. That search introduced him to American National Manufacturing’s fledgling brand, Instant Comfort, and Wall’s Relax in Comfort still sells Flex-Head® Smart Beds every single day.

For today’s bedding industry leaders, this story is more than historical—it offers a roadmap for innovation. Wall’s early recognition of the need for personalized yet shared comfort helped reshape adjustable sleep systems. His journey is a reminder that solving customer problems is central to our mission. Whether it’s called Split Top, Flex-Head, or something else, the design bridges the gap between individual control and the emotional value of sleeping together.

As demand for customization continues to grow, manufacturers and retailers have a clear opportunity: embrace designs that support individual needs without sacrificing connection.





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