Recycling PU Mattress for Real World Footwear Applications Promoting Circular Economy

Slips and falls are a major safety issue, and conventional outsole materials often fail under wet or oily conditions. I developed composite filaments by blending TPU with carbon fiber, PBO, and recycled polyurethane. Using Fusion 360 for outsole CAD design, Cura for slicing, and Instron tensile/MAA slip testing systems, I created and validated sustainable, high‑traction footwear prototypes.

• Modeled outsole tread geometries in Fusion 360 and prepared prototypes with Cura slicing for FDM printing

• Produced and tested 27 outsole prototypes, improving slip resistance by >15% MAA score using slip‑resistance testing rigs

• Reduced virgin polymer use by 50% through recycled PU integration, validated with Instron mechanical testing