Polyurethane (PUR) products used in construction, automotive, and furniture sectors are traditionally fossil-based and often lack performance and sustainability. BIOMAT addressed this by establishing an Open Innovation Test Bed (BIOMAT-TB) to support SMEs and industries in developing nano-enabled bio-based PUR foams and composites. Through a Single Entry Point (SEP), users accessed pilot-scale production lines and services such as characterisation, nanosafety, standardisation, business planning, and mentoring.
The project was structured around nine objectives:
O1 – Establishment of the BIOMAT-TB and SEP:
A fully operational test bed and SEP platform were created, with 13 partners providing services. A business model and sustainability plan were developed.
O2 – Implementation of the Open Tender:
Two Open Calls attracted 14 applications. 7 SMEs received tailored technical and business services, validating the SEP’s functionality.
O3 – Development of Digital Twin Pilots (DTP) and inline monitoring:
A Digital Twin Platform was developed with 6 generic and 22 ad-hoc models. Inline spectroscopic sensors (UV-Vis and NIR) enabled real-time monitoring and optimisation, improving reproducibility by 27% and reducing offline measurements by 60%.
O4 – Scale-up and characterisation of foam components:
12 pilot lines were upgraded (TRL 6-7) to produce bio-based components such as polyols, lignocellulosic adhesives, and nanofillers, demonstrating feasibility at pre-commercial scale.
O5 – Scale-up and validation of bio-based PUR foams:
Soft, semi-soft, rigid, and spray foams, as well as insulation aerogels, were scaled up and validated, showing improved thermal and mechanical performance.
O6 – Demonstrators in operational environments:
10 demonstrators were validated. In construction, mock-ups in Spain and Latvia showed improved insulation. In automotive, seat components met industry standards. In furniture, products showed high comfort and durability.
O7 – Recycling, nanosafety, and standardisation:
Microwave-assisted glycolysis achieved 53% energy savings. Recyclates were reused without performance loss. Five air monitoring campaigns and toxicological assessments confirmed safety. A new standard (CWA 50751:2024) was published.
O8 – Environmental and economic sustainability:
LCA, LCC, and SLCA confirmed lower environmental impact and competitive costs. Market analysis and value chain assessment supported the business plan.
O9 – Dissemination, exploitation and communication:
The project produced 20 publications, participated in 65 events, attracted over 11,000 SEP possible clients, and created 3 demonstration videos. A strategic exploitation plan was developed, with 11 technologies ready for transfer and a customer database of over 9,000 contacts.
BIOMAT demonstrated that sustainable, high-performance PUR materials can be developed and scaled through a collaborative, innovation-driven ecosystem, contributing to EU goals for circular economy and climate neutrality.
