Tocco Report: FOAM 2.0

New Materials for Foam in Design and Performance

Foams are everywhere. We walk on them, sleep on them, ship with them—and expect them to perform without fanfare. From the midsole of a high-performance sneaker to shock-absorbing inserts in packaging, sound-insulating architectural panels, or the soft core of medical orthotics, foam is the quiet workhorse of modern design. Its appeal lies in contradiction: soft yet strong, voluminous yet lightweight, protective yet invisible.

This report by Tocco team explores the evolving role of foam materials across industries—how their composition, performance, and environmental impact are being redefined. We investigate innovations in bio-based foams, recyclable alternatives, and circular design strategies that challenge the dominance of petroleum-based standards. At a time when softness can no longer come at the cost of sustainability, foam is being reimagined from the inside out.