Fraunhofer LBF Develops Bio-Based Polyurethane Foam for Upholstery and Industrial Use

Materials researchers at the Fraunhofer Institute for Structural Durability and System Reliability LBF have developed a flexible polyurethane foam composed of more than 90% bio-based raw materials, intended to replace petroleum-derived foams across furniture, automotive seating, and industrial applications. Developed under the OrganoFoam project alongside industry partner Friedrich Platt GmbH, the material is formulated to match the seating comfort, operational lifespan, and manufacturing behavior of conventional polyurethane foams.

As reported by TechXplore (https://techxplore.com/news/2026-10-upholstery-foam-bio-based-ingredients.html), the development centers on combining bio-based polyols with bio-based isocyanates. While those two components are typically utilized in rigid industrial coatings rather than flexible cushioning, the research team created a patent-pending formulation that yields a resilient, open-cell foam requiring only minimal additives.

"These two components are normally used to make coatings and are not actually suitable for flexible foams. However, by developing a specially tailored formulation, which we are having patented, we were still able to create our sustainable foams," said Roland Klein, a research scientist at Fraunhofer LBF in Darmstadt. "They are over 90% bio-based and contain only a few additives."

Unlike many sustainable cushion alternatives, the formulation does not rely on embedded natural fibers for structural support. In laboratory production, the reaction mixture expands into foam blocks weighing up to 8 kilograms (18 pounds). Once demolded, workers mechanically crush the blocks to open the internal pore structure, establishing dimensional stability so the material resists warping, heat expansion, and cold contraction.

Processing and comfort assessments conducted at Friedrich Platt GmbH demonstrated that the laboratory-produced blocks can be cut using standard industrial converting machinery, joined with adhesives into larger cushion assemblies, and wrapped in standard upholstery fabrics. User trials on a demonstration sofa confirmed seating and lying comfort comparable to fossil-based reference materials.

In accelerated weathering evaluations using ultraviolet lamps, the bio-based material demonstrated enhanced UV resistance. Conventional polyurethane foams turned yellow and brittle after 100 hours of exposure, whereas the OrganoFoam formulation showed minimal discoloration after 700 hours. Compression hardness and compression set testing confirmed mechanical performance on par with petroleum-derived flexible foams.

Beyond residential furniture and vehicle interiors, project researchers identified potential applications across protective packaging, acoustic building insulation, and medical positioning aids.