V-Foam: The world’s first economically recyclable polyurethane foam

Together with BASF, Vitra has developed a polyurethane foam that can be recycled and reused in the same consistent quality. Jasmin Jouhar spoke about this innovation with Harald Gerwig, Global Head of Technics at Vitra.

Jasmin Jouhar: Polyurethane foams (PU foams) have long been used as a proven upholstery material in many Vitra products. What are their key advantages?

PU foams are safe, versatile and adaptable in their use. They can be modified to create materials with different properties and are extremely durable, maintaining their consistent quality and performance over decades.

Even in the case of intensive daily use, such as the upholstery for an office chair?

Yes. That's why PU foams are so widely used, for example in mattresses.

Are there any disadvantages to the material?

A major disadvantage is that standard PU foam is so stable in its chemical composition that it cannot be recycled by melting – unlike thermoplastics such as polypropylene. We have repeatedly searched for other recyclable upholstery materials, but there is simply no equivalent alternative.

But mechanical and chemical recycling processes do exist for PU foams. How do they work?

It is possible to produce new composite foams by shredding used foams into flakes, which are then compressed and bonded with adhesives. However, this type of material is not suitable for upholstery. It can be used for soundproofing applications or as a filler. PU foam can be chemically recycled back into its individual components, but this requires so much energy that the process is not economically viable.

What are the distinguishing characteristics of the new recyclable polyurethane V-Foam?

BASF has worked with Vitra to develop a meltable polyurethane. After use, it can either be liquefied to make new PU foam or processed into granules for the production of injection-moulded components.

That sounds very promising ...

The sole disadvantage of PU foams has been eliminated. In my opinion, there is no better upholstery material. This closes the material loop and conserves resources: we take existing raw materials and create new plastics from their recyclates.

Can V-Foam be reused in its entirety?

Yes, we can recycle the material without compromising its properties. And it can also be processed using the existing mechanical and chemical recycling methods. There are no limitations.

Why did BASF approach Vitra for a collaboration?

BASF and Vitra have been partners for many years. We have been developing products together since the 1960s, such as the Panton Chair. I think BASF values Vitra as a brand and for our expertise. We are pioneers when it comes to applying innovative technologies and materials. In addition, our Test Center has the necessary infrastructure to experiment and evaluate new products.

V-Foam will initially only be used for office chairs and armchairs such as the Eames Lounge Chair. Why is that?

Smaller products like these require foam components that we can produce in our own facilities. Larger foam parts, such as for sofas, come from external suppliers. They will also be converting their production in collaboration with BASF.

Vitra will have exclusive use of the material for one year ...

Yes, we wanted a limited period of exclusive use for the development and implementation phase. But of course the impact is greatest if as many companies as possible manufacture their products from meltable PU foam, including in the automotive sector or the mattress industry – so that one day only this type of PU foam will be available for recycling.

Do you see any long-term alternatives to today's fossil-based upholstery foams?

Vitra is always on the lookout for alternative raw materials. Up to now, none have been able to match the qualities of PU. But as the saying goes, perfect is the enemy of the good! So we'll keep at it and continue our research.