BASF Announces Novel Low-VOC Catalyst for Flexible Polyurethane Foams

On September 14, 2026, BASF introduced a new catalyst with low VOC content for making flexible polyurethane foam. The catalyst is designed to help with the chemical reactions during foam formation and allows manufacturers to achieve consistent results, especially in processing and final product quality. Foam producers currently face high pressure to create cleaner formulations, especially for products used in consumer goods, homes, and vehicles.  

This product addresses growing concerns in the industry about emissions, odor, and material performance. It can be used in cushioning, mattresses, furniture, and automotive interiors, where controlling VOCs and odor can benefit both the products and the manufacturing process. Overall, this technology gives formulators another option for developing foams with lower emissions, without sacrificing key performance features.

Impact on the Furniture and Home Furnishing Sector

The global furniture and home furnishing store market size accounted for USD 542.23 billion in 2025 and is predicted to increase from USD 565 billion in 2026 to approximately USD 816.02 billion by 2035, expanding at a CAGR of 4.17% from 2026 to 2035.

According to Precedence Research, furniture makers and the home furnishing sector could benefit from a catalyst that helps create flexible polyurethane foams with lower emissions and less odor. Foam producers can use this technology to develop products that meet consumer demand for superior indoor air quality.

This is especially vital for sofas, chairs, cushions, and other upholstered items used indoors. The real benefits will depend on how the catalyst fits into well-established formulations, production conditions, testing needs, and the cost of adding it to current processes. Additionally, consistent reaction control can help ensure reliable foam properties during manufacturing.

Impact on the Latex Mattress Sector

The global latex mattress market size was calculated at USD 12.27 billion in 2025 and is anticipated to reach around USD 19.77 billion by 2035, expanding at a CAGR of 4.89% between 2026 and 2035.

According to Precedence Research, the mattress industry could gain another formulation tool as manufacturers increasingly consider VOC emissions and odor alongside comfort, flexibility, and durability. A low-VOC catalyst may help foam producers develop materials with improved emission characteristics and offer the properties required for sleeping surfaces and support layers.

Adoption will depend on whether manufacturers can achieve the desired emissions profile without affecting foam performance and production efficiency. Lower odor could influence consumer perception, especially when latex mattresses are used soon after purchase. Testing of finished mattresses will be highly central because catalyst performance determines overall product emissions.

Impact on the Automotive Interior Materials Sector

The global automotive interior materials market size is estimated at USD 68.31 billion in 2026 and is anticipated to reach around USD 96.41 billion by 2035, expanding at a CAGR of 3.9% from 2026 to 2035.

According to Precedence Research, automotive suppliers might consider using this catalyst for flexible polyurethane foams in seats, headrests, acoustic parts, and interior cushioning. A low-emission catalyst can help produce foams for demanding interior uses and help suppliers meet changing material standards from car manufacturers.

Car makers are focused on cabin air quality, so controlling VOCs and odors during the construction of automotive interior materials. But before it is widely used, automotive applications will require thorough testing for emissions, odor, processing, durability, safety, and compatibility with each vehicle program.

Expert Opinion

From an expert point of view, the introduction shows that the development of polyurethane catalysts is gradually transitioning from a focus on reaction speed and foam performance to a more comprehensive balance between manufacturing efficiency and emissions control. For producers of foam, a catalyst with low VOC content will be valuable provided that it ensures reliable processing and at the same time helps to reduce unwanted emissions and odour in the final products.

The catalyst should be considered only one element of a broader formulation strategy in foam chemistry and feedstock procurement. The most promising area seems to be those in which indoor and cabin air quality has a direct impact on the choice of materials. The conditions under which it is produced, and its behaviour after production, all influence the final emissions. Finally, successful commercialization will depend on measurable performance, formulation flexibility, and competitive edge during manufacturing practices.