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From textile waste to acoustic panels—BAUX upcycles polyester and creates sound insulation

The article discusses BAUX's innovative Acoustic Felt, a sound solution made from 100% traceable recycled polyester sourced from textile offcuts. BAUX, a venture by industrial design studio Form Us With Love, aims to create sustainable acoustic building materials by repurposing textile waste, a significant global problem contributing 92 million tonnes of waste annually. Fredrik Franzon, head of product and founding partner at BAUX, emphasizes the challenge of tracing recycled materials and the brand's commitment to circularity. BAUX collaborated with The Loop Factory to source 100% polyester-based threads from Swedish textile manufacturer Ludvig Svensson. This collaboration allows for a small, traceable manufacturing network, avoiding reliance on larger, less transparent processing facilities. The process involves hand-sorting textile offcuts by color, followed by an undisclosed treatment that enables material reuse while maintaining original quality. These treated offcuts are then combined with energy-efficient polyester fibers to form the material's structure, a process designed to accommodate varying fiber qualities and minimize additional waste. The fibers are locally dyed in Sweden, adhering to strict environmental regulations, and the resulting material is pressed into molds and cut into nine different sizes suitable for desk dividers and wall panels. Prioritizing function, the BAUX Acoustic Felt range is flexible, easy to handle, and modular, allowing for quick scaling. The design eliminates the need for glue or hardware, promoting repurposing and reuse. This approach addresses common office environment challenges and sets new standards for business-as-usual practices. The hardware pieces are standardized for effortless setup and reduced production waste, contributing to a completely traceable source from industrial production facilities that would otherwise discard and incinerate the waste. This marks a crucial step towards BAUX's long-term goal of achieving full circularity. The Acoustic Felt is one of BAUX's collections, complementing their 2019 Acoustic Pulp panel, which uses 100% biodegradable and organic content for high sound absorption. BAUX's core values include innovation, adherence to circularity principles, waste reduction, and the development of new product categories to meet future architectural demands. The material development involved BAUX and Form Us With Love for product design, and The Loop Factory for sustainable material, product, and technological solutions. BAUX aimed to offer a novel product that pushed boundaries in sustainability and features, recognizing the market's need for traceable and truly sustainable felt products despite felt's inherent absorptive, shaping, and aesthetic qualities. The problem addressed was the difficulty in tracing the origin of recycled materials, a lack of demand from the market on businesses, and the traditional use of mixed synthetic fibers in industrial felt. Without control over material components, there's a risk of sourcing from corrupt supplies, potentially increasing plastic production and compromising circularity. BAUX solved this by securing a completely traceable source from industrial facilities, controlling the content of their recycled products, and preventing textile waste from being incinerated. The manufacturing process involves collecting textile offcuts from Ludvig Svensson, hand-sorting them, treating them, mixing them with low-melt polyester fiber to produce a nonwoven sheet, pressing it into a rigid sheet, and water-jet cutting it into various sizes. The materials used include 40% textile offcuts (Oeko-Tex® Standard 1000 certified, REACH-compliant dyeing chemicals), 50% thermoplastic fiber (CO-PET/PET), and 10% polyester fiber (PET). The innovation lies in the treatment method that allows for the reuse of textile offcuts, resulting in a 100% traceable and recycled product designed for longevity and adaptability within office spaces, with components that are easy to update, replace, and extend. #TextileRecycling #AcousticPanels #SustainableDesign #CircularEconomy #RecycledPolyester #MaterialInnovation #InteriorDesign #OfficeDesign #SoundInsulation #TextileRecycling #AcousticPanels #SustainableDesign #CircularEconomy #RecycledPolyester #MaterialInnovation #InteriorDesign #OfficeDesign #SoundInsulation
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