EcoLattice Showcases Sustainable Foam Alternative at London Design Festival

Polyurethane foam, widely used in furniture, vehicles, and footwear, is a persistent environmental challenge. Derived from petrochemicals, it is hard to recycle, emits volatile organic compounds during use, and contributes significantly to landfill waste. As the global push toward net zero intensifies, designers and manufacturers are searching for viable alternatives that reduce both carbon intensity and end-of-life impact.

At the 2025 London Design Festival, the Aram Gallery presented “Beyond Foam”, an exhibition showcasing EcoLattice, a 3D-printed material that could replace conventional polyurethane foam in upholstered products. Developed by Yash Shah, a Central Saint Martins graduate, EcoLattice is made from thermoplastic elastomers, some sourced from recycled automotive waste and TPU used in phone cases. The result is a material that maintains flexibility and comfort while offering improved recyclability and lower embodied carbon.

Eight UK-based designers, including Arianna Kilachand, Harinad PM, Maria Bravo, Richard Price, Rupert Warries, Shivangi Vasudeva, Tom Howell-Jones, and Tomas Thorsson, tested EcoLattice across a range of seating prototypes. These included ergonomic chairs, loungers, and innovative stress-relieving designs. The aim was to push the material’s technical and creative limits, demonstrating both comfort and industrial scalability.

EcoLattice differs from conventional foams by being digitally designed and additively manufactured. This allows for precise control over density and resilience, reducing raw material use while enabling reuse and recycling at the end of life. Such advances could help reduce waste and emissions in furniture manufacturing, a sector often overlooked in carbon accounting but significant due to the volume of polyurethane used globally.

Daniel Aram, managing director of Aram, said that modern foam’s poor biodegradability and chemical off-gassing create long-term waste and health concerns. He believes that showcasing alternatives like EcoLattice could encourage manufacturers to pilot sustainable materials. According to market data, the global flexible polyurethane foam market exceeds 10 million tonnes annually, with demand projected to rise. Replacing even a portion with recyclable, lower-carbon options could cut millions of tonnes of CO₂ equivalents each year.

EcoLattice’s approach also has implications beyond furniture. Thermoplastic elastomers are already used in automotive and footwear industries, where weight reduction and recyclability matter for sustainability and cost. If adopted widely, lattice-structured cushioning could reduce reliance on virgin petrochemicals, simplify disassembly, and improve circularity.

The initiative aligns with broader European Union and UK goals to reduce landfill waste and support circular economy models. Extended producer responsibility (EPR) regulations being considered for furniture could push companies to adopt materials that can be recovered or remanufactured at the end of life. Additionally, corporate net zero commitments are driving interest in innovative materials that deliver measurable carbon savings.

“Beyond Foam” is on view at Aram Gallery in London until 11 November 2025, giving industry stakeholders a chance to experience the material firsthand. The exhibition includes a “Material Playground” where visitors can handle samples and test comfort levels, a key factor for potential adoption in commercial production.

For furniture and automotive companies seeking to decarbonize, materials like EcoLattice highlight the potential of design-led sustainability. By combining digital manufacturing with recycled content and end-of-life recoverability, such innovations offer practical steps toward emissions reduction and waste minimization. Scaling these solutions will require further collaboration among designers, suppliers, and manufacturers, but the early prototypes suggest a credible path away from petroleum-based foams.

Source: wallpaper.com