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Compared to traditional fossil fuel derived expanded foams, and to more sustainable variants containing approximately just about 20-30% of bio-based material, Agoprene represents a novelty in the sector, thanks to a biogenic composition that reaches up to 85%. The foam, made mainly from seaweed, has been designed to replace polyurethane (PU) foams and demonstrated a 100% biodegradability in internal studies, thanks also to the absence of harmful or petroleum-based chemicals.
The primary component is Norwegian kelp, to which mineral fillers derived from seashells and by-products of the Norwegian paper industry are added. These elements, when mixed together, create a paste that is then subjected to an expansion process using water injection and air foaming, which gives the foam its lightness, elasticity and porous structure.
At the current stage, this bio-foam is manually produced, following an artisanal process. However, the company is already in a scale-up phase, focused on introducing increasingly automated systems, with the aim of optimising production flows and ensuring standardisation of formats in the coming months.
Specifically, the aim is to produce ready-to-use sheets in order to simplify the application phases and reduce processing times. Thanks to these characteristics, the material can be used in various industries: from furniture upholstery to padding for accessories and textiles, and even in the packaging sector.
The foam is produced in rolls and usually supplied in standard sheets with a width of 2 meters and a thickness varying between 2 millimeters and 5 centimeters, with 10 cm of thickness achievable with the stacking of multiple layers. Interestingly, this innovative material has demonstrated workability also via moulding techniques, despite possible shrinkage may limit shape design and production rates.
The start-up’s sustainable approach delivers an interesting alternative in the market of technical components for furniture and interiors, whether it is needed for flat, cushioning surfaces, or flexible, curved structures. Moreover, according to an internal LCA, Agoprene showcases a carbon footprint that is approximately one third of polyurethane foam manufactured via conventional processes.
Designers and creatives have thus a new, forward-thinking option available for their project: a transformative choice that bridges the gap between creativity, technical challenges, and eco-conscious design.
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https://designwanted.com/agoprene-sustainable-padding-applications/
