VAUDE Mono‑Material TPU Backpack: Fully recyclable high‑performance outdoor pack introduction

VAUDE set out to design a backpack where every textile, fastening, padding, and coating derives from a single polymer family. The goal was to maximize end of life recyclability without sacrificing the durability, comfort, and weather protection that outdoor enthusiasts demand.

Designing a mono material backpack meant tackling every step of development through the lens of a single polymer family. The team first had to identify a TPU grade versatile enough to deliver tear resistant fabrics, abrasion proof shell panels, and breathable cushioning – roles traditionally spread across multiple materials. This requirement drove material scientists and product designers to develop novel processing techniques, such as fusion welding in place of adhesives and a bespoke Parallel Layer Manufacturing (PLM) method for cushioning, while preserving the performance outdoor users expect. 

Covestro’s Desmopan® TPU portfolio provided VAUDE with a unified material platform. Key components include:

TPU Yarn for the Fabric

Utilizing TPU based yarn in place of nylon or polyester, VAUDE engineers wove a durable, elastic textile that maintains excellent tear strength, weather resistance, and 100 % recyclable credentials.

100 % TPU Tarp as Outer Shell

The backpack’s exterior is a robust TPU tarp film that offers superior abrasion resistance, flexibility, and waterproofing. Its inherent toughness shields gear from rain, mud, and rugged outdoor conditions.

Desmopan® AIR Cushioning

For shoulder straps, back panels, and hip belts, Desmopan® AIR TPU granules are converted into lightweight, breathable padding via a novel Parallel Layer Manufacturing (PLM) extrusion process. The result is washable, hygienic cushioning that retains softness and shock absorption without compromising mono material recyclability.