Designing the Future of Flight with Vera Klerken

Bacterial Cellulose in the Embraer E195-E2 seats

At Foamlab, we are always exploring how to push the boundaries of what bio-based materials can do. A recent collaboration with industrial designer engineer Vera Klerken for her TU Delft MSc graduation project, alongside aerospace manufacturer Embraer, provided the perfect opportunity to take our bacterial cellulose (BC) foam out of the lab and into the sky.

Vera’s thesis investigates how Color, Material, and Finish (CMF) design can function as a measurable sustainability lever in short-haul aviation. Her project focuses on integrating different BC material variants into aircraft seating for the Embraer 195-E2, with KLM Cityhopper serving as the case study.

Bio-Innovation Takes Flight

The aviation industry currently relies heavily on fossil-based polyurethane (PU) foams for seat cushioning, materials associated with high embodied emissions and significant recycling challenges. By exploring the potential of bio-based BC materials, Vera's project demonstrates a pathway toward more circular aircraft interiors.

Using the Materials Driven Design (MDD) method, Vera developed four distinct variants of our BC material to replicate various seat components:

• Soft BC Foam: High compressibility and elastic recovery for seat pan and headrest cushioning.

• Hard BC Foam: A high-density, rigid core for structural seat pan support.

• BC Leather Alternative: A flexible surface material with high tensile strength for upholstery.

• Rigid BC Material: A dense morphology designed to replace ABS plastics in parts like tray tables and armrests.

Seat design for the Y-Class. Image credits: Vera Klerken

Seat design for the W-Class. Image credits: Vera Klerken

Seat design for the J-Class. Image credits: Vera Klerken

Measurable Sustainability

The impact of this material shift was quantified through an operational Life Cycle Assessment (LCA). By replacing conventional PU-based materials with these lighter BC alternatives, the design achieves a 58% weight reduction compared to the original components.

When scaled across the industry, the environmental benefits are substantial:

• 355,000 kg CO₂ saved per aircraft per year.

• 9 million kg CO₂ saved for the total KLM Cityhopper E195-E2 fleet per year.

• 59 million kg of CO₂ saved per year for the entire global Embraer 195-E2 fleet currently in operation.*

*based on modeled LCA scenarios

Elevating Passenger Experience

Sustainability in this project goes hand in hand with an enhanced passenger journey. Vera’s three-class CMF concept—Dutch Discovery (Y-Class), Crocus Comfort (W-Class), and Vermeer Vesper (J-Class)—was validated through perceptual studies with travelers. The results showed that her designs were consistently preferred over current interiors, with comfort and cleanliness emerging as the most significant drivers of a positive experience.

Image credits: Vera Klerken

We are proud to have collaborated with Vera on this project, which earned her a 9.5/10 and a cum laude degree. Her work reinforces our belief that materials are the key to shaping both a sustainable and emotionally resonant future.

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Explore the project further

Read Vera's full thesis on the TU Delft Repository.