PET (polyethylene terephthalate) is the most widely recycled plastic in the world. The volume of waste makes an abundant supply of re-useable material that can be given a new life and recycled after use. It is a chemically inert substance making it safe and stable for use in the home.

We have chosen to work with PET felt because of its inherent properties, and how well it compliments the application for pets and interiors.

Let's take a look behind the scenes at how Noah is made, and what makes Noah unique.

PET fibres are mixed with more non-woven fibres and evenly distributed to make a fine web, slowly increasing the material’s strength with layers. The fine webs are layered one on top of another and carded to make the wadding.

A punching process is later performed over the wadding, using barbed needles to press the fibres.

The needling process increases the wadding density, making it more compact. This technique ensures exactly the right density, weight and thickness across the sheet for Noah.

Needling removes any need for additional glues and binders reducing the material makeup, keeping it clean and simple.

The wadding is thermo-pressed into flat sheets, or thermo-formed into our shell using a large press. The felt is cooled by the mould after pressing, and the shell retains its shape.

Manufacturing with this method is a low energy system, and we use both processes for the base and shell.

Noah's profile is cut seamlessly using a pressurised beam of water inside an automated cutting station. The base is cut separately using a similar procedure on a flatbed.

Any offcuts are removed and recycled. These can be melted as a polymer and used elsewhere or ripped up, carded and used again.

The shells and bases are later stacked to reduce the storage footprint and prepared for shipping.