Process || EcoLattice

From Foam to the Future

At EcoLattice, we merge circular design, sustainable materials, and digital technology to reimagine foams. We are committed to creating durable, recyclable, and customisable alternatives to polyurethane by reclaiming waste elastomers and transforming them into 3D-printed lattices. We turn discarded plastics into high-performance products while our digital tools ensure precision, personalisation, and zero-waste production.

Step 1 Raw Material
Waste (TPEs)

We begin with post-consumer products and post-factory trims, collecting thermoplastic elastomers (TPEs) and carefully segregating them by Shore hardness.

Step 2 Shredding

The sorted TPEs are mechanically shredded into pellets—an essential step for stable processing.

Step 3 Adding Additives

Special additives and foam elements are introduced to stabilise the material and add softness. This unique blend makes EcoTPU distinct from conventional foams.

Step 4 Precise Filament Production

The pellets are processed into highly precise filaments, critical for FDM printing. EcoTPU filaments are refined through accurate molding for consistent printability.

Step 5 Filament
to Lattice

Using customised 3D printers, the filaments are digitally transformed into lattice structures—the building blocks of our foams. CAD models in STL or STEP formats guide the process.

Step 6 Final Foam

The lattice foams are finished with light post-processing, resulting in custom-made products tailored to design requirements.

Step 7 Pressure Data Collection

We capture pressure data from users through mats or pressure-sensitive sheets for our tailor-made products. This information enables ergonomic optimisation in each creation.

Step 8 Digital Customisation

Using parametric design tools like Rhino and Grasshopper, the pressure data is converted into varying density zones within the foam for a truly bespoke experience.