It was back in 2023 that the Pearson Lloyd Edge system expanded to include our first foam-free seating, Edge Free. We asked Luke Pearson and Tom Lloyd to tell us what it takes to bring a low carbon, foam free product to life.

“The interaction between people, product and place – and how a product or system can affect our behaviour – lies at the heart of our practice.” It is this mantra that sits as a core principle of Pearson Lloyd’s approach and one that was applied to the development of Pearson Lloyd Edge, a comprehensive and flexible workplace furniture system that we launched in 2015.

It all started with a knuckle,” says Luke Pearson with a chuckle. “Or more precisely, a corner knuckle.” This knuckle is in fact the cast aluminium piece that forms the corner joints of the system – the meeting point for the extruded horizontal supports of each product and the sturdy legs. The design is underpinned by these carefully engineered structural components but is nevertheless imbued with a visual simplicity. The strength of the knuckle gives the system the potential for multiple products, always carried off with a coherent visual identity.

“The idea of shifting from traditional polyurethane (PU) foam to natural fibre alternatives came from our commitment to reducing the environmental impact of our products. While commonly used for its comfort and resilience, PU foam is derived from petrochemicals. We wanted to explore materials that were renewable, biodegradable, and had a lower carbon footprint during production and disposal. Natural fibres, like coconut coir, offered a compelling alternative due to their availability as waste materials, their durability, and minimal environmental impact. This aligns with our broader sustainability goals, aiming to design with a circular economy in mind—prioritising recyclable or biodegradable materials and reducing reliance on finite resources."

"Although coconuts grow in tropical regions far from most manufacturing locations, coconut fibre, or coir, is a byproduct of the food industry. Unlike PU foam, which involves energy-intensive processes with significant greenhouse gas emissions, coconut coir is a natural waste material that would otherwise go unused. Coir is biodegradable, whereas PU foam usually ends up in landfills where it can persist for centuries. The environmental footprint of transporting coconut fibre is far outweighed by the reduced impact associated with its production and end-of-life disposal. Using coconut fibre also supports local economies in low-middle income countries.

It is likely that the UN treaty to end plastic pollution will eventually impact the manufacture of furniture. As global awareness of the environmental and health impacts of plastic pollution grows, regulations aimed at reducing or eliminating the use of harmful plastics will become more stringent. The future role of plastic in furniture will shift towards more sustainable and circular applications. While the use of virgin plastic may decline due to environmental concerns and regulatory pressures, recycled and bio-based plastics will become more prevalent. Plastics may still be used where their properties—such as durability, flexibility, and lightweight nature—are essential, but with an emphasis on designs that facilitate recycling and reuse."

"The furniture industry, like others, will need to adapt by finding alternatives to traditional plastic materials, increasing the use of recycled or bio-based content, and designing for easier disassembly and recycling, both of which we are starting to see.

Manufacturers will also need to adopt more transparent practices, ensuring that their materials and processes align with emerging regulations and consumer expectations for sustainability. This shift could drive innovation in materials science, encouraging the development of new, sustainable materials that can replace plastics while maintaining the functionality, durability, and aesthetics required for high-quality furniture.”

Pearson Lloyd is a product, furniture and innovation design studio led by founders Luke Pearson and Tom Lloyd, and run from a studio in Shoreditch, East London. For the last twenty years, the agency has designed products, systems and environments for the home, workplace, transport and healthcare sectors. Its close relationship with clients, including consumer brands, manufacturers and retailers has given the agency unparalleled experience in understanding the needs of users and the demands of business.

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This article was originally included in our new publication, Material Intelligence | Design Understanding.

Read on below to gain an in depth understanding of our products and guiding company and sustainability principles.