Foam materials are a staple in countless industries, from furniture and interior design to footwear and packaging. However, traditional foams often rely on petroleum-based plastics, leading to significant environmental challenges, including non-biodegradability and microplastic pollution. Enter FoamPrint3D, a spin-off company from the University of Twente, aiming to revolutionise foam manufacturing with biobased, 3D printed alternatives that align with circular design principles.

A New Era of Foam Production
FoamPrint3D introduces a versatile platform for creating more sustainable foam products using vegetable oils and other renewable materials. These biobased foams are designed to match the performance of conventional counterparts while being fully biodegradable and free from harmful additives. Unlike traditional foams that require high-energy manufacturing processes, the 3D printing technique enables precision production with minimal waste.

Co-founder Olivier Ingouin, a materials science expert, explains, “The key innovation lies in the printer itself and the unique biobased materials we developed. The system enables designers and manufacturers to create bespoke foam solutions on demand while reducing their carbon footprint.”

Applications Across Design Disciplines
The customisability of FoamPrint3D’s technology opens doors for applications in diverse design fields. In architecture and interior design, biobased foam can be used to create acoustic and thermal insulation panels that not only improve indoor air quality but also contribute to meeting sustainability goals, such as achieving green building certifications. In product design, the technology supports the development of ergonomic furniture, lightweight components, and shock-absorbing elements tailored to specific requirements, empowering designers to innovate while maintaining a commitment to sustainability.

In the fashion and footwear industry, FoamPrint3D offers solutions such as customisable insoles and footwear components, benefiting individuals with specific needs like foot-related health conditions. These innovations align with the growing demand for circularity in fashion. For packaging designers, the foam’s biobased and recyclable properties make it ideal for protective packaging, offering a sustainable alternative in the ever-expanding e-commerce and shipping sectors. Automotive designers can also benefit from this technology, as lightweight biobased foam contributes to energy-efficient vehicle designs by reducing overall weight while providing soundproofing and cushioning capabilities.

Bridging Innovation and Sustainability
FoamPrint3D’s development reflects a broader push towards integrating sustainability into material innovation. By leveraging biobased inputs, the company tackles the dual challenge of reducing reliance on fossil fuels and creating materials that can naturally decompose at the end of their lifecycle. Moreover, the 3D printing process itself supports on-demand production, reducing waste and allowing manufacturers to print only what is needed.

A Vision for the Future
FoamPrint3D’s founders are not just focused on the practicalities of material production; they envision a world where sustainable foams can become the default option across industries. By partnering with programmes like Novel-T and BeStart, the company is poised to bring its technology to market while raising awareness about the importance of circular design.

As Olivier notes, “We believe these materials can do more than replace conventional foams—they can inspire designers and manufacturers to rethink how products are made, used, and eventually returned to the environment.”

Source: University of Twente News
Photos: FoamPrint3D