Advanced TPU material for SCF foaming technology
Footwear Evolution: Performance, Sustainability, Efficiency
Today’s consumers expect footwear that performs on every level—from athletic output and impact protection to lightweight comfort in daily wear. The midsole plays a central role, delivering energy-return, cushioning, and durability across use cases. Purchasing decisions are increasingly influenced by environmental impact, with growing attention to how products are made.
This dual challenge requires footwear brands to adopt advanced materials that deliver performance while supporting smarter, cleaner, and more scalable manufacturing.
Driving Midsole Innovation: Advanced TPU Solutions for SCF foam injection moulding
Supercritical fluid (SCF technology is transforming midsole production with enhanced performance and eco-friendly benefits. Applicable in both autoclave and direct injection processes, direct injection stands out for production efficiency through reduced cycle times and fewer processing steps while delivering consistent quality outcomes.
Covestro’s Desmopan® FLY TPU is specifically engineered for SCF foam injection molding, with a polymer structure that enables exceptional supercritical fluid dispersion and uniform fine-cell foams. This creates midsoles with outstanding mechanical properties that meet leading footwear brands’ high-performance specifications while requiring fewer manufacturing steps, reducing lead times and ensuring consistent quality.
Sustainable Manufacturing with Better Recyclability and Lower Energy Use
Desmopan® FLY TPU eliminates the need for chemical blowing agents in injection moulding technology, potentially reducing chemical additives while enabling recyclability of the midsole. When combined with a TPU outsole, this creates a closed-loop material pathway supporting circular economy initiatives.
SCF foaminjection moulding is a highly automated physical foaming process that integrates multiple footwear components in a single molding step, eliminating cementing and assembly while reducing energy use and carbon footprint, this eco-friendly manufacturing approach creates uniform fine-cell structured foams with superior cushioning and energy-return, enabling brands to accelerate production of lightweight, high-performance, sustainable footwear.
We're seeing growing demand for materials that deliver both elite performance and sustainability. Desmopan® FLY unlocks new possibilities with optimized processing, offering lightweight resilience, long-term durability, and efficient recyclability to help shape the future of high-performance footwear.
High-Performance TPU for Exceptional Cushioning and Energy Return
While sustainability matters, product performance remains consumers’ top priority in footwear. Midsole made from Desmopan® FLY TPU delivers superior cushioning, energy return, and lasting comfort for both everyday consumers and performance athletes.
The material's unique microcellular structure ensures dimensional stability and durability throughout the product lifecycle, maintaining excellent energy return and structural integrity during strenuous use, while resisting compression over time.
Local Investment Enables Efficient Production and Stable Supply
Unlike chemical foaming, SCF technology requires advanced equipment and tighter process control. Covestro has installed the advanced foam injection molding system at its TPU Asia-Pacific R&D Center in Taiwan—a strategic hub in the global footwear supply chain.
This state-of-the-art facility enables comprehensive R&D support and rapid application services for customers’ specific requirements, while enabling local-to-local supply capabilities that reduce logistics costs, accelerate commercialization and enhance competitiveness for footwear brands in a fast-paced market.
Key benefits
- More sustainable: Zero chemical blowing agents and recyclable components
- High-performance: Delivers superior cushioning, energy return, and lasting comfort
- Efficient production: Highly automated with less production steps
- In-house SCF technology: Enables real-time simulation and seamless collaboration with brands
