Finding alternatives to traditional plastic foams is one of the big challenges facing designers and manufacturers seeking to lower the impact of their work when working with plastics. The most commonly used polyurethane foams are, of course, derived from petrochemicals, often using hazardous chemicals during production. Foams can emit volatile organic compounds during use and often end up in landfill or incinerated after use as they are difficult to recycle.
Plant-based foams are an emerging category although many of those on offer are not fully biodegradable or recyclable. One company addressing this challenge is Natural Fiber Welding who offer a range of materials made primarily from plants including Tunera foam. The Illinois-based manufacturer claims Tunera ‘is made from a combination of natural rubber, vegetable oil, minerals and cork and will biodegrade at end of life and can even potentially be recycled. Originally developed for use in footwear the company claims the material is suitable for use across a range of applications including upholstery. No chemicals of concern are used in the manufacturing process.
Natural Fiber Welding prides itself on developing materials designed ground up to be scaled. The company already has 40 brands and 70 products as clients. Their first product, Mirum, is claimed as the first 100% biobased leather alternative and has been used by footwear manufacturers (including Australian brand Bared) among others.
The company adopts a strong ethical stance across its supply chain. Rubber used in the production of Tunera is partly sourced from farmer cooperatives using regenerative practices in Thailand. Energy consumed during the production of materials is offset with wind-powered renewable energy credits. Water use, which is not needed for most products including TUNERA, is minimized through closed-loop production. The company was recognized as a finalist in the 2024 Earthshot Awards.