Has anyone had to do a return with UPS shipping to SleepWarehouse or another place with a large box? I just checked on shipping rates to return my 3” King Sensus topper and UPS charges a premium for a box over 24”x24”x24” and I’m pretty sure the box the topper came in was larger. I’m at work now and the box is at home, so I can’t be positive, but I’m pretty sure the box was closer to 30”x30”x30” or more. The original shipping and weight was $23.85 and 55 lbs. For a box larger than 24”x24”x24”, UPS charges a minimum billable weight of 140 lbs. and a “Large Package Surcharge” to bring my final cost to $111 in shipping to return my topper. SleepWarehouse obviously didn't pay that.

How do you have the latex memory foam packed? Is it vacuum bagged to its smallest possible size? That big of a piece has got to be a bear to pack.

It's actually memory foam. I haven't packaged it yet, but when it came, it wasn't vacuum-packed that tight like my PU from FBM. I was folded in three's each way.

My box was 25 inches square - I had our shipping department check it out at work, and the UPS software didn't include a surcharge. I really thought the box was bigger - hopefully I can get the topper back in it.

Was it inside a plastic bag? If so, you can use a vacuum sweeper hose attachment to shrink it down just enough to fit it in the box. Vacuum bagging it really should not hurt the foam at all.

Well, I decided to package up my King size 3” Sensus topper today. I’ve had it folded in two spots from head to foot for the last two days and covered on the floor with extra bed sheets around it for protection. Realizing that to fit it back in the box properly, I would probably need to have the first two folds starting from the sides and not head to foot (as it was originally shipped) since the next set of folds are going to be wider folds along the 80” of the topper. So, I proceed to fold it twice along the 76” width...no problem. Then I continue to fold twice along the 80” height, but after the first fold I noticed multiple small tears about 1/8” deep along the fold. I’m assuming that folding it possibly caused stress to the foam, or maybe it was too cold in my room at the time...I’m not sure??? I’m a little stressed now about possibly losing $350, but I don’t know what I could’ve done differently. I did previously email SleepWarehouse for instructions on returning the topper, but they just replied with a return address and no special instructions for folding this thing back up. I plan on calling them tomorrow and explaining the situation. Does anyone else have experience with returns at SleepWarehouse? Hopefully good experiences?

That's interesting about the "cracks" in the memory foam. That shouldn't happen. I have frozen, crushed with my shoe, and twisted my sample of Sensus like I was wringing the water from a chamois, and there isn't a mark on it.

It surprised me, but it does make sense that it happened. On that first fold of the second set of folds (top to bottom), I was dealing with 9" of foam. I would've had to have somehow compressed the inside of the fold so that the outside wouldn't stretch. I think memory foam was made to compress, but not stretch in that way. It's like Flexographic label printing - that's the kind of printing I do digital prepress for. The "Flex" in Flexographic refers to the plating process. When I output a job, the plate has to be reduced in the direction it is mounted around the printing cylinder because it is a raised image...almost like a rubber stamp. For example, a .067" thick plate that is 6" repeat around a cylinder has to be distorted (or flexed) in that direction only to 93.51% so that the outside of the plate will be 6" when wrapped around the cylinder, but the inside will be 5.6106". I do vaguely recall reading a post  (not sure if it was on this site) about someone that folded up their Sensus and put it in their closet and it tore where it was folded from stress. I believe they said Fomax replaced it for them???