Covestro Unveils Lightweight, Recyclable TPU for Footwear

Covestro has introduced Desmopan® FLY, a new series of thermoplastic polyurethane (TPU) materials specially designed for supercritical fluid (SCF) injection foaming. This advanced technology is used to make lightweight, strong and sustainable products, especially in footwear, sports gear, furniture, and electronics.

The new material allows for uniform, fine-cell foam structures, giving footwear excellent cushioning, energy return and long-lasting comfort. Since no chemical blowing agents or crosslinkers are used, the soles are easier to recycle. Combined with soft TPU outsoles, they support a circular economy.

“Leading sports brands are driving unprecedented demand for materials that combine elite performance with strong environmental credentials,” said Wilson Chan, Head of Business Development TPU Asia Pacific at Covestro. “Desmopan® FLY brings exceptional lightweight and resilience properties while maintaining dimensional stability and durability throughout the product lifecycle. Its optimized processing enables efficient production through automated injection molding, allowing brands to create high-performance, recyclable footwear that meets demanding consumer expectations.”

To support this innovation, Covestro has set up its own SCF injection foaming system at its TPU R&D Centre in Taiwan. This facility helps develop new applications quickly and ensures consistent quality.

“Our investment in the SCF injection foaming system marks another milestone in Covestro’s continuous innovation journey,” said Dr. Christian Haessler, Head of Global Innovation TPU at Covestro. “This in-house capability enables us to optimize TPU material properties with precise SCF processing parameters. By being among the first in the industry to integrate this advanced technology within our R&D center, we can effectively combine TPU material and SCF injection expertise to accelerate customers’ development from concepts to commercial production.”

This new method also helps lower the carbon footprint by using less energy and fewer production steps. Automated injection moulding allows for efficient, high-quality production in one go.

Desmopan® FLY is now available and supported by Covestro’s technical experts and modern facilities. It offers sports brands a new way to meet performance and environmental goals more effectively.