Orabona Federica: Biomass-derived non-isocyanate polyurethane foams :catalysis, formulation and product characterization: 3000 eur

Green synthesis of non-isocyanate polyurethane foams from biomass-derived building blocks Success story 

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 a urgent need to shift toward isocyanate-free alternatives. 

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. 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. 

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.