Beyond Foam by Ecolattice at Aram

Beyond Foam by Ecolattice at Aram

‘Beyond Foam’ sets out to address the challenges posed by conventional polyurethane foam, a material widely used in furniture design. Developed during his time at Central Saint Martins, materials engineer Yash Shah presents a 3D-printed lattice alternative that rethinks traditional foam through innovations such as variable shore hardnesses and circular design principles. The installation showcases this new material through playful, interactive elements and original works by nine emerging product designers. Together, they encourage visitors to rethink the materials we interact with daily, offering a fresh perspective on designing for comfort.

About EcoLattice:

The EcoLattice Material System: A Smart Alternative to Conventional Foams

At first glance, EcoLattice may resemble and feel like foam, but look closer, and you’ll find a completely reimagined material system built for the future. Unlike conventional polyurethane (PU) foams, which are poured into fixed moulds, bonded to wood, and destined for landfill, EcoLattice is an adaptive, circular, and intelligent structure designed for precision comfort and planetary care.

The innovation lies in the lattice itself. Using pressure data collected from real human bodies, EcoLattice employs generative software tools like Rhino and Grasshopper to translate sitting postures into bespoke 3D-printed forms. This process ensures every cushion delivers targeted support and optimal pressure diffusion, improving posture, breathability, and long-term comfort. The material doesn’t just feel better; it performs smarter.

Made from recycled TPU (thermoplastic polyurethane), EcoLattice foams are more durable, fire-resistant and water-resistant. No adhesives means no disassembly challenges and no toxic off-gassing—problems that plague conventional foams. Unlike PU, which deteriorates over time and cannot be recycled once bonded, EcoLattice foam can be returned, remelted, and reprinted in a closed-loop cycle. Even manufacturing waste is collected and reintegrated, creating a near-zero-waste system.

Traditional foam cannot replicate EcoLattice’s function or form. The performance comes not just from material choice, but from geometry. Lattice structures enable strategic flexibility and compression set, where needed, while remaining lightweight and breathable. Additive manufacturing allows for rapid iteration and avoids the long timelines, high costs, and environmental burden of tooling and mould-making.

Each product takes fewer hours to print and can move from concept to completion quickly. This eliminates the need for physical prototypes and over-engineering, making space for mass customisation while having no post-processing. This streamlined digital-to-physical pipeline makes the production process as responsive as the material itself.

EcoLattice is not just a new way to make foam—it’s a system-level rethink. It balances circularity, customisation, and performance without compromise, offering a scalable and sustainable path forward for industries like furniture, mobility, and wellness. As a technology, it signals a move toward Industrial Revolution 5.0: human-centred, data-driven, and planet-positive.

Smarter by design, sustainable by nature—EcoLattice is foam, evolved.