Federica Orabona: Biomass-Derived Non-Isocyanate Polyurethane Foams: Green Synthesis and Material Innovation

Biomass-Derived Non-Isocyanate Polyurethane Foams: Green Synthesis and Material Innovation

By Federica Orabona

Overview

My PhD research focuses on transforming renewable and waste-derived resources into safer materials for everyday use.

Polyurethane foams are among the most widely used polymeric materials due to their exceptional versatility, finding applications in furniture, mattresses, building insulation, and footwear. Despite their widespread use, conventional polyurethane foams are produced from fossil-based resources and toxic isocyanates, posing concerns for both human health and the environment. There is therefore an urgent need to shift toward isocyanate-free alternatives.

Research & Innovation

Within this project, non-isocyanate polyurethane (NIPU) foams have been successfully developed through the valorization of biomass-derived materials such as vegetable oils, limonene, and lignocellulosic resources.

These renewable feedstocks are converted into key chemical intermediates and used to produce fully isocyanate-free polyurethane foams, significantly reducing dependence on crude oil and eliminating hazardous chemicals from the production process.

Results

The resulting materials achieved a high bio-based content of 90–98% while maintaining good mechanical flexibility and thermal stability.

An additional key outcome of the project is the demonstration of NIPU foam reprocessability into new generation materials, highlighting their potential for recycling and reuse and supporting circular material design.

Impact

The support of the Walter Ahlström Foundation has been essential in advancing this research by enabling my participation in international scientific conferences, where I shared my results with the wider research community, as well as supporting a nine-month research visit in Italy that significantly strengthened the experimental work and international collaboration.