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CIRCULAR DESIGN INITIATIVE

Pure Progress

BigAirBag's shift towards circular design - switching to stronger, lighter,
and more circular airbag systems.

THE WHY

Why are we doing this?

At BigAirBag, progression has always been at the core of what we do. We build products that help athletes, riders, and operators push forward with confidence, knowing they can rely on safe, high-performance landing systems.

But progress should not stop at performance alone.

As the industries we work in evolve, so does the responsibility that comes with building the products behind them. The materials we use, the way our products are designed, and what happens to them over their full lifetime matter more than ever.

That is why we started the Circularity Initiative.

This is not a marketing campaign or a small product update. It is a long-term commitment to rethink the foundations of our products and move toward a model that better reflects where our company, and our industry, needs to go.

We believe progression should never come at the expense of performance, people, or the planet.

Performance

Materials should enhance product performance, not limit it. Our new direction delivers measurably better results.

Longevity

Products that last longer reduce the need for replacement – and the waste that comes with it.

Waste Reduction

Linear production creates end-of-life problems. We’re designing with the full lifecycle in mind.

Future Responsibility

The industry is evolving. We want to lead that change, not react to it later.

THE SHIFT

From linear materials to circular
design

We are moving away from conventional PVC-based construction and toward a PP-based material direction that supports lighter, stronger, and more recyclable airbags. This shift creates the foundation for simpler material systems, better end-of-life pathways, and a more circular product model overall.

CONVENTIONAL APPROACH

  • PVC-based material construction
  • Heavier overall build
  • Mixed-material complexity
  • Limited recyclability at end of life
  • Linear product lifecycle

NEW CIRCULAR DIRECTION

  • PP-based material direction
  • Lighter, stronger construction
  • Mono-material potential
  • Better suited for recycling
  • Designed with full lifecycle in mind
  • Built for more responsible end-of-life outcomes

KEY BENEFITS

Performance meets responsibility

Stronger

PP delivers a higher tensile strength and up to 3 times greater tear resistance than PVC. Making the PP airbags tougher and more durable.

Lighter

Using a lighter material helps reduce overall weight, making airbags easier to transport, install, handle, and potentially less resource-intensive across their lifecycle.

Designed for Circularity

Our mono-material PP construction makes the main material easier to recycle, reuse, or down-cycle. While the airbag is not yet fully closed loop, this shift supports future closed-loop recovery by reducing the need for complex material separation.

Better Recyclability

PP is widely recyclable and compatible with existing recycling systems, simplifying end-of-life processing.

Lower impact

At the material production stage, PP is estimated to have a nearly 60% lower CO₂ footprint than PVC.

Built for Long-Term Use

A more durable material helps improve resistance to wear and repeated use. Combined with our commitment to repair and service airbags wherever possible, this supports longer use and helps reduce unnecessary waste.

CIRCULARITY MODEL

The BigAirBag circularity model

We are building a circular take-back model designed to keep materials in use for longer, prioritise repair over replacement, and create a responsible recovery pathway at end of life.

1. Source Material
We source PP-based material from trusted suppliers as the starting point for a more circular product system.

2. Manufacture
That material is transformed at the BigAirBag factory into high-performance airbags designed for durability, serviceability, and improved future recyclability.

3. Use
The airbag is installed and used by the customer in demanding environments, with a use phase of up to 10 years depending on application, wear, and maintenance.

4. Service & Repair
We are committed to servicing and repairing airbags wherever possible to keep them in use for as long as possible and reduce unnecessary replacement.

5. Buy-Back
When an airbag reaches the end of its usable life, we aim to buy it back based on product size so it can enter a responsible end-of-life pathway.

6. Recycle & Recover
Recoverable material is sent to recycling partners, where it is processed into recycled pellets or downcycled into other products, helping keep material in circulation.

7. Residual Waste
Not all parts can currently be recycled. Any remaining non-recyclable elements are separated and handled as residual waste.

DATA DRIVEN

What the data shows so far

We are taking a data-driven approach to this transition. Some differences between PVC and PP are already clear at the material level, while other outcomes are still being measured through testing, lifecycle assessments, and partner validation.

Roadmap

Where we are now

This is a journey, not a finished claim. Here's our progress and what comes next.

PP Material Research & Development
We are sourcing and developing a polypropylene-based material specifically designed for airbag production.
Pilot Testing & Refinement
We will test the new PP base material in real operating environments and refine it based on performance data.
Transition from PVC to PP
In Progress
After validation, all new airbags will be produced using PP material as the base, replacing PVC in future production.
Airbag System Recyclability & LCA
We will conduct a Life Cycle Assessment of the full airbag system, including all components, to understand its footprint and identify the next steps toward improved sustainability.
Blower Efficiency Improvements
We will improve blower efficiency to reduce energy waste during use and lower the overall environmental impact of the system.
Recyclable Topsheet Development
We will research and develop a topsheet material that can be recycled and integrated into future products.

Will the new material perform the same as the previous PVC airbags?

The new PP airbags will perform even better than the previous PVC ones, because of the higher tensile and tear strength.

What makes this material more sustainable than PVC?

The PP material is recyclable at the end of the product life cycle, where PVC is only partially recyclable.

How is the 50% CO₂ reduction calculated?

The 50% CO₂ reduction is calculated by comparing the total lifecycle emissions of our previous PVC airbags with our new polypropylene (PP) airbags. This includes raw material production, manufacturing, transport, and end-of-life processing.

Has the material been tested in real training environments?

The material has been thoroughly researched and tested in real training environments.

Will it handle heavy daily use from athletes?

It has been tested in high throughput environments, the results showed less wear than on a PVC airbag in the same environment.

Will the price of the airbags change with this new material?

The price of the new airbags will stay the exact same as before.

How is the airbag recycled at the end of its life?

The airbag will be send back to BigAirBag, we will pass it on to a recycling company that is specialised in recycling PP materials.

Is the installation or setup different from previous airbags?

The installation, setup and operating of the airbags will stay the same. It will even be easier , because the PP airbags are lighter than the PVC ones.

Does maintenance or repair change with the new material?

Maintenance and repair are still possible if needed.

Why is BigAirBag making this change now?

We have helped the world of action sports and leisure progress with our products. Now it is time to for us to help the environment progress.

Are other airbag companies doing the same?

No other airbag company is making the switch towards recyclable materials.

Further questions?

Do you have any further questions about our circularity program, please let us know.

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