Over 20 Kg Per Mattress New Tech Turns Waste Foam into 98 Percent Usable 3D Material

Polyurethane foam, widely used in everything from car seats to mattresses, has posed a major recycling challenge for decades due to its complex chemistry. With millions of mattresses discarded each year, each containing 15–20 kg of foam, the environmental impact is enormous. But recent innovations are beginning to transform this persistent waste into valuable resources.

At the Indian Institute of Science (IISc) in Bangalore, a breakthrough has been achieved. A research team led by Professors Suryasarathi Bose and Subodh Kumar has developed SaLSO, a patented process that converts polyurethane waste into 3D printing feedstock. The technique works by selectively breaking the chemical bonds within the foam, allowing it to be reduced to its basic components, which can then be reused.

Unlike traditional mechanical recycling—which involves cleaning and melting—the chemical recycling approach decomposes plastics back into their original monomers, allowing for high-quality material regeneration. SaLSO stands out with a conversion efficiency of up to 98% and compatibility with various foam hardness levels. It also works on other hard-to-recycle plastics such as epoxies, unsaturated polyesters, and polyolefins.

This shift toward chemical recycling marks a critical step forward in plastic waste management. As Prof. Bose puts it, “We now have a sustainable solution that turns previously non-recyclable materials into valuable 3D printing products. This isn’t just recycling—it’s upcycling.”

With global plastic waste piling up and recycling rates still low, breakthroughs like SaLSO could redefine how industries handle discarded polymers, creating both environmental and economic value from what was once landfill-bound.