Material innovation: developing Autex Acoustics’ first truly circular acoustic material

3 July 2024

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“Circularity means considering the entire lifecycle of a product, not just how it will be used in the first instance.” Sam Wells, Autex Acoustics’ Product Development Lead, is talking about the company’s mission to create truly circular acoustic products—a response to the growing market demands for environmentally conscious building materials.

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“Our team does a lot of market research, and while we saw the demand for a circular solution, it had been something that we were already looking into. Creating sustainable solutions is something we are passionate about, so the timing was perfect. Through testing, conversations with industry peers and prototyping, we have developed innovative technology and industry-first materials that repurpose waste PET material.”

The materials, ReForm™ and RePET, which were innovations from our material exploration project, are both made entirely from repurposed acoustic PET material. ReForm utilises reclaimed and recyclable acoustic material retrieved through the Autex Acoustics’ Takeback Programme, while RePET recycles our production trimmings into a pelletised form, which can be used to create product components and accessories.

“As ReForm and RePET use reclaimed textile materials, it recycles waste that would otherwise go to landfill, extending its life. This provides another stream for product waste to be reused and given a new life as acoustic solutions that can continue to be recycled over and over again. These are the first reclaimed materials we have developed, and we’re constantly looking at the various ways we can expand our range of solutions with these materials in the future,” Wells says.

The material exploration process was not without challenges. To deliver solutions made entirely from reclaimed material, Autex Acoustics’ needed to establish a viable manufacturing process, run a functioning takeback programme, and ensure the finished product would meet current building standards.

“The research and development stage includes a lot of trial and error. We did plenty of testing of the material’s capabilities and got a lot of feedback from the market. Speaking to those who will be specifying and using the products made from these materials was crucial. They can give us a perspective and insight that we may not have thought of before.”

ReForm and RePET are an important developments for Autex Acoustics®, not only because they are diverting waste from landfill—necessary in a country where 50% of landfill waste is generated by the construction industry—but because they open the door for a new era of sustainable product development.

“In the creation of something like ReForm, there is a lot more to it than just an acoustic solution. It is a part of a larger system that we have designed to close the loop on construction waste,” Wells explains.

There are few materials that architects and designers can specify that truly encompass closing the loop. While ReForm and RePET are important milestones, it is a step in our larger sustainability journey. We have, and will continue, to innovate in this space—helping reduce not only our own impact, but others in our industry, too.”

The future of materials like ReForm and RePET include expansion as Autex Acoustics looks for ways to close the loop at home and further afield.

“Systems need to be developed so that more materials can be recycled. There is always going to be room for products to improve, and so we need to keep pushing the boundaries of what we have achieved.”