Lear’s engineering team set out to design a recyclable, foam-free seating material that could deliver comfort and performance comparable to conventional solutions, while addressing long-term sustainability requirements. The result is FlexAir™, a 100% recyclable, 100% breathable, foam-free alternative that combines advanced polymer science with a unique extrusion process.

As the industry’s first extruded 3D loop polyethylene cushioning, FlexAir delivers luxury comfort, durability, and lighter weight — while meeting the rigorous performance standards of modern vehicles. By integrating air, polyethylene loops, and Lear’s materials expertise, FlexAir establishes a new benchmark for seating innovation with both commercial and environmental benefits.

Through an innovative design and production process, FlexAir combines air, advanced polymer science, and Lear’s seating expertise to achieve a technology that is lighter in weight and engineered to meet the rigorous performance standards of modern vehicles.

Innovation Backed by Science‍

FlexAir is more than a chemistry change or subtle shift in processes. It’s a transformation powered by:

• More than 450 patents, protecting innovations across comfort, durability, environment and recycling qualities.
• A water-based extrusion process that produces resilient, lightweight loops engineered for long-term comfort.
• Provides up to 20% weight reduction and improved durability compared to traditional materials
• Volatile Organic Compounds (VOC) emissions below 1% compared to traditional materials, creating a safer work environment for employees

Sustainability with Proof‍

FlexAir is 100% recyclable — a true foam-free alternative that reduces CO₂ emissions by up to 50% compared to traditional seat cushion materials. This innovation has the potential to divert up to 2.5 billion pounds of waste annually from landfills. By eliminating liquid resins and enabling circularity through solid pellets, FlexAir supports a cradle-to-cradle lifecycle for seating materials.‍

Partnership Power‍

This breakthrough was made possible through Lear’s seating expertise and a partnership with Dow MobilityScience, which together advanced the material architecture and processing required to meet stringent automotive standards.‍

On the Road & Scaling Fast‍

As automakers set ambitious goals for carbon reduction and recyclability, innovations like FlexAir will play an increasingly important role. With commercial applications already underway and multiple global OEM programs in development, FlexAir represents a step forward in aligning seating technology with the mobility industry’s objectives.