OrganoFoam - Flexible polyurethane foams made from renewable raw materials

Sustainable Seating and Lying Down

Upholstery for furniture, mattresses, and vehicle seats consists primarily of petroleum-based PU foams. Those who wish to offer their customers sustainable products are therefore faced with the question of how to replace fossil-based raw materials with renewable alternatives without compromising on comfort, durability, or workmanship. The “OrganoFoam” project has developed novel polyurethane flexible foams that consist largely of bio-based raw materials and can be manufactured and processed just like familiar standard foams.

From the Lab Bench to Upholstery Applications

It all began with the idea of combining natural fibers with a bio-based foam to create a load-bearing support structure. As the project progressed, however, it became clear that a carefully formulated bio-based foam formulation could achieve the resilience typical of seating and reclining furniture even without fibers. To achieve this, we varied foam formulations and process parameters across numerous laboratory trials as part of a systematic testing program. The result is a soft foam that is foamed into blocks weighing up to eight kilograms, mechanically “crushed” after demolding to open up the cell structure, and subsequently remains dimensionally stable.

The “OrganoFoam” blocks produced in this way have densities comparable to those of standard furniture-grade foams and a fine-pored, predominantly open-cell structure. Measurements of compression hardness and permanent deformation show that selected formulations achieve the performance characteristics of a fossil-based reference foam. Accelerated weathering tests also demonstrate that the bio-based foam yellows significantly more slowly than many conventional foams and can be further protected from UV radiation through the use of suitable additives.

Comfortable, durable, bio-based - a foam for many industries

For foam processors, furniture manufacturers, and seating manufacturers, it is particularly important that “OrganoFoam” can be integrated into existing production processes without major changes. Tests conducted at Friedrich Platt GmbH show that the supplied blocks can be easily cut to size using existing systems, bonded together to form larger surfaces, and laminated with standard upholstery fabrics. As part of the project, a demonstration sofa was created to test seating comfort and long-term durability under real-world conditions.

“OrganoFoam” is suitable for manufacturers who want to strengthen their brands with credibly sustainable lines of furniture, seating, and mattresses. The high proportion of biogenic carbon and improved UV resistance contribute to a positive carbon footprint and a long service life. In the future, additional applications are conceivable, such as in medical positioning aids, acoustic damping elements, or shock-absorbing packaging, where soft, durable, and sustainable foams are in demand.

Funding and Partners

OrganoFoam “Sustainable Upholstery for the Furniture and Automotive Industries” was funded by the German Federal Ministry of Research, Technology and Space (BMFTR) pursuant to a resolution of the German Bundestag.

Grant Number: 031B1248A.

Project Partner: Friedrich Platt GmbH