Researchers at the Fraunhofer Institute for Structural Durability and System Reliability LBF have developed a flexible polyurethane foam, called OrganoFoam, that contains more than 90% bio-based material, PU Magazine reported on 6 October 2026. The patent-pending formulation combines bio-based polyols and bio-based isocyanates with a small proportion of additives. According to the institute, the predominantly open-cell foam provides the resilience needed for mattresses, upholstered furniture and vehicle seating.
The raw materials are normally used in coatings and are not inherently suited to flexible foam, so the institute developed a formulation tailored to the application. Foam blocks weighing up to 8 kg were produced in the laboratory and then mechanically crushed to open the cellular structure and improve dimensional stability. German foam processor Friedrich Platt cut, bonded and upholstered the blocks using existing industrial equipment, and a demonstration sofa was built.
Compression hardness and compression set tests indicated that the fine-pored foam could compete with a conventional fossil-based reference material, Fraunhofer said. In accelerated UV ageing, conventional foam turned yellow and brittle after 100 hours, while OrganoFoam showed little discoloration after 700 hours. The project was funded by the German Federal Ministry of Research, Technology and Space.
The work is at laboratory scale, and the report does not mention a commercial launch or a timetable. For flexible foam processors the points of interest are the reported compatibility with existing cutting, bonding and upholstery equipment and the use of bio-based polyols and isocyanates that are usually found in coatings.