Wacoal and BASF Extend ‘Melooop’ Technology into Automotive Interiors with TPU-Based Armrest Concept

Wacoal and BASF have expanded their long-standing collaboration beyond apparel applications by introducing an innovative automotive interior armrest concept based on Wacoal’s proprietary ‘Melooop’ technology and BASF’s Elastollan® thermoplastic polyurethane (TPU).

The concept demonstrates the potential of advanced three-dimensional fiber-based manufacturing to create lightweight, comfortable, and highly design-flexible automotive components. Originally developed for lingerie applications, Melooop is a unique three-dimensional fiber molding technology that employs a melt-blown nonwoven process to simultaneously form and layer fibers into complex structures in a single manufacturing step. The technology eliminates the need for adhesives and multi-layer assembly, reducing production complexity, material consumption, and waste while supporting improved recyclability through mono-material design.

By integrating BASF’s Elastollan® TPU, the process combines thermoplastic processability with elastomeric performance, enabling durable yet flexible structures that maintain their shape and comfort under repeated use. The companies highlighted that the technology allows designers to optimise thickness, weight and material properties early in the development process, helping automotive manufacturers balance performance, durability and sustainability requirements.

For occupant-contact surfaces such as armrests, the resulting structures offer soft-touch comfort, excellent elastic recovery and long-term dimensional stability. BASF noted that the project reflects its commitment to collaborative innovation and sustainable materials development, while Wacoal views the initiative as a significant step in extending its expertise in comfort-focused product design into new industrial sectors. The armrest concept showcases how advanced material solutions and novel manufacturing technologies can support the development of lighter, more resource-efficient and recyclable automotive interior components for future mobility applications.

Source: BASF