Re-Mat: Reinventing Circular & Functional Mattress for the Health-care Sector

Mattresses for the healthcare sector are designed for robust use with a core foam layer and a polyurethane-coated polyester textile cover. Nurses and surgeons indicate that these mattresses are highly uncomfortable to patients because of poor microclimatic management (air, moisture, temperature, friction, pressure regulation, etc) across the mattress, which can cause pressure ulcers (in less than a day). The problem is severe (e.g., extra recovery time, medication, increased risk, and costs) for patients with wounds, infection, pressure-sensitive decubitus.

There are around 180,000 waterproof mattresses in the healthcare sector in the Netherlands, of which yearly 40,000 mattresses are discarded. Owing to the rapidly aging population it is expected to increase the demand for these functional mattresses from 180,000 to 400,000 in the next 10 years in the healthcare sector. To achieve a circular economy, Dutch Government aims for a 50% reduction in the use of primary raw materials by 2030. As of January 1, 2022, mattress manufacturers and importers are obliged to pay a waste management contribution.

Within the scope of this project, we will design, develop, and test a circular & functional mattress for the healthcare (cure & care) sector. The team of experts from knowledge institutes, SMEs, hospital(s), branch-organization joins hands to design and develop a functional (microclimate management, including ease of use for nurses and patients) mattress that deals with uncomfortable sleeping and addresses the issue of pressure ulcers thereby overall accelerating the healing process. Such development addresses the core issue of circularity. The systematic research with proper demand articulation leads to V-shape verification and validation research methodology. With design focus and applied R&D at TRL-level (4-6) is expected to deliver the validated prototype(s) offering SMEs an opportunity to innovate and expand their market. The knowledge will be used for dissemination and education at Saxion.

Mattresses currently used in hospital and care environments are known to be functionally inadequate and environmentally unsustainable. Typically constructed from polyurethane (PU) foam with PU-coated polyester covers, these mattresses lack adequate breathability, moisture regulation, heat accumulation, friction, and uneven pressure distribution (poor microclimate management). As a result, they contribute to the development of pressure ulcers, particularly among patients who are bedridden or in recovery. Additionally, the use of mixed materials makes recycling extremely difficult, which leads to substantial environmental impact.
The ReMat project was initiated to address these issues through the development of a circular and functional mattress tailored to the needs of the healthcare sector. Bringing together a consortium of researchers, industry partners, healthcare professionals, and design experts, the project set out to co-develop a mattress system that is both technically and environmentally superior to conventional options. The resulting prototype features a multi-layered mono-material cover and a highly breathable 3D polyester spacer fabric core. This design enables effective microclimate management by allowing airflow and vapour transmission, which are critical for the prevention of pressure ulcers. The materials used are fully recyclable, and the construction allows for disassembly using standard tools. Importantly, the entire system adheres to European medical device regulations and ISO standards.
Advanced assembly methods such as ultrasonic welding and the exclusion of harmful adhesives further contribute to hygiene and circularity. The mattress can withstand hospital-level cleaning and has demonstrated improved pressure distribution and comfort in testing.
By addressing both functional and environmental challenges, the ReMat project has validated a viable path toward circular innovation in medical textiles. The outcomes offer promising opportunities for scaling and adoption in healthcare settings, where demand for sustainable and patient-centred products continues to rise. The project also contributes to national goals for material reuse and reduction of healthcare waste.