A 3D printed tool insert made with polyphenylene sulfide (PPS) using Arburg Freeformer. It has adequate heat resistance for moulding prototypes in silicone and certain thermoplastics.
Wastea vegan leather made with bio-based polyurethane resin (bio-PUR) and waste tea leaves. A durable and resilient material, it is suitable for applications in fashion, apparel, interiors, furniture, upholstery and automotive.
A Decathlon trainer with thermoplastic polyurethane (TPU) foam midsole. The textile upper is placed in the mould along with the durable TPU outer sole, and over-moulded with TPU using Mucell physical foam technology. This creates a lightweight and durable shoe with excellent rebound and recovery.
Circle Supernatural running show with thermoplastic elastomer (TPE-TPA) foam midsole made with Arkema Pebx Rnew, a partially bio-based elastomer. The knitted textile upper is placed in the mould along with the durable TPE outer sole, and over-moulded with TPE using Mucell physical foam technology. This creates a lightweight and durable shoe with excellent rebound and recovery.
Hexpol Dryflex Circular recycled thermoplastic elastomer (rTPE) samples made by 3D printing. The saturated colour is possible due to the high quality scrap material used.
Exotech folding fins injection moulded in DuPont Hytrel thermoplastic elastomer (TPE-TPC). This version, called Eco-B, is equivalent in performance to those made from fossil feedstock, but with biomass content up to 72 % by weight. DuPont produces Hytrel Eco-B using a biomass balance approach certified by the ISCC+ (International Sustainability & Carbon Certification) standard.
A power tool housing injection moulded in 30% glass fibre reinforced polyamide 6 (PA-GF30). A combination of additives and surface texture help to conceal the visual impact of the fibres.
Senoplast Senosan high impact acrylonitrile butadiene styrene (ABS) co-extruded with thermoplastic elastomer (TPE-TPS) and thermoformed into an automotive interior component. While the ABS provides impact strength and rigidity, the TPE contributes a tactile and durable surface.
Flex Tube from Studio About by Mikkel Lang Mikkelsen features an LED light in a silicone rubber tube that can be bent and draped. It is waterproof and so can be used outdoors.
Dodge ski boots featuring Bond Laminates glass and carbon fibre reinforced thermoplastic polyurethane (TPU) upper, and polyurethane resin (PUR) 3D dome logo sticker
Positive Plastics injection moulded sample of Desmopan thermoplastic polyurethane (TPU) by Covestro. This family of materials offers high wear resistance, flexibility across a wide range of temperatures, and high elasticity over a wide hardness range. They also possesses excellent resistance to oils, greases, solvents and weathering.
Positive Plastics injection moulded sample of Apilon 52 bio-based thermoplastic polyurethane (bio-TPU). This family of material includes soft and rigid grades (ester, ether, ester-ether-based). The broad range of properties possible makes this material suitable for footwear and in leather goods. Beyond this Apilon 52 can also be used in automotive and engineering, cosmetics and personal care, medical, packaging, sporting goods, toys and gadgets.
TPU Evolution knitted trainer upper by Coatyarn. Thermoplastic polyurethane (TPU) textiles offer excellent resistance to abrasion, hydrolysis, UV rays, weathering, aging, wear and tear, combined with comfort and drape. As a thermoplastic it is recyclable and may be laminated with heat and pressure alone (without adhesive).
TPU Evolution knitted jacket by Coatyarn. Thermoplastic polyurethane (TPU) textiles offer excellent resistance to abrasion, hydrolysis, UV rays, weathering, aging, wear and tear, combined with comfort and drape. As a thermoplastic it is recyclable and may be laminated with heat and pressure alone (without adhesive).
Orthopaedic insoles made of BASF Elastollan thermoplastic polyurethane (TPU). The sole is produced by 3D printing, using fused deposition modelling (FDM), which makes it possible to produce an ultralight cushioning structure tailored to an individual's needs. A low density area can flow smoothly into firm support, helping to stabilise the foot. The open grid allows for breathability. As a shoe sole material, TPU offers excellent vibration dampening and resilience, even with fluctuating temperatures. Image BASF.
Orthopaedic insoles made of BASF Elastollan thermoplastic polyurethane (TPU). The sole is produced by 3D printing, using fused deposition modelling (FDM), which makes it possible to produce an ultralight cushioning structure tailored to an individual's needs. A low density area can flow smoothly into firm support, helping to stabilise the foot. The open grid allows for breathability. As a shoe sole material, TPU offers excellent vibration dampening and resilience, even with fluctuating temperatures. Image BASF.
Moulded shoe soles with up to 30% recycled material. BASF has developed polyurethane resin (PUR) foams with thermoplastic properties that can be processed together with thermoplastic polyurethane (TPU) in the injection moulding process. Image BASF.
Thermoplastic elastomer (TPE) shoe sole, based on styrene (SEBS), shaped by injection moulding. The upper of these high tops is produced from polyurethane resin (PUR) faux leather.
The Nike+ Fuelband activity tracker, launched 2012, is encapsulated within a thermoplastic elastomer (TPE) skin. A flexible circuit board is mounted onto an injection moulded polypropylene (PP) chassis. The whole assembly (circuit board, processor, sensors, antenna, USB connector and LED lights), but excluding the batteries, is placed into a mould and injection over-moulded with a TPE skin in a two-stage process (inside then outside).
Nike Running trainers featuring a foamed ethylene vinyl acetate (EVA) sole with integrated thermoplastic rubber (TPR) outer layer based on styrene (SEBS), shaped by injection moulding.
Michelin Pilot Sport tyre. The two main synthetic rubbers in car tyres are polybutadiene rubber (BR) and styrene butadiene rubber (SBR). They are typically used in combination with around 20% natural rubber (NR). Tyres used in more demanding applications, such as trucks and aircraft, contain a higher proportion of natural rubber. A whole host of other materials and additives are used, including steel cable, reinforcing textile and fillers (predominately carbon black and silica for conductivity and enhanced resistance to tearing and abrasion) to give the desired performance. Image Michelin.
The core of a golf ball is typically polybutadiene (PB) or a blend of synthetic rubbers. A mantle is moulded around the core, creating a perfect sphere and providing a bridge between the rubber core and plastic cover. Softer balls may have more layers. The cover is moulded over the top with the characteristically dimpled texture. It is typically either polyurethane resin (PUR) or Surlyn ionomer. The graphics are pad (tampo) printed onto the cover and sealed with a high-gloss coating.
NRS paddle shoe. They are produced with Terraprene, a neoprene derived from limestone and recycled tyres. Other examples of neoprene made from limestone include Bioprene and Geoprene. Image NRS.
TIPSiV injection moulded elastomer is a hybrid of thermoplastic polyurethane (TPU) and silicone produced by Dow Corning. It combines the benefits of TPU with the unique tactility and durability of silicone. It takes colour well and is resistant to fading.
Nelson Bubble Lamp, by George Nelson for Herman Miller, 1952, formed by spraying a polyvinyl chloride (PVC) mixed with a webbing agent (which causes the PVC to form filaments) onto a steel wire frame, and finished with a layer of pure PVC spray coating
The Tesla Model 3 features Tabu wood veneer, dyed to look like walnut, laminated onto an injection moulded carrier. The instrument panel (dashboard) consists of an injection moulded structure, soft foam layer and durable surface foil. The materials for this type of dashboard are typically polycarbonate alloy (PC/ABS) carrier, polyurethane resin (PUR) foam, and thermoplastic polyurethane (TPU) foil.
Cross section through an automotive instrument panel (dashboard) featuring BASF Elastoflex polyurethane resin (PUR) foam. This is a safety critical part of the design, as well as important visual and tactile aspect, sitting in front of the driver. In must be able to tolerate some demanding conditions - temperature extremes, direct sunlight and heat through the windshield - while maintaining its appearance for the life of the vehicle. They are made with various material technologies, such as with unpainted polypropylene (PP), or as is the case with higher spec vehicles like this example, using PUR foam between an injection moulded structural carrier and tactile surface foil. The foam bonds the carrier, which is typically PP or polycarbonate blended with acrylonitrile butadiene styrene (PC/ABS), to the surface foil to create a smooth profile with soft touch feel. Surface foils include thermoplastic olefin (TPO), and slush moulded thermoplastic polyurethane (TPU) or polyvinyl chloride (PVC). Image BASF.
Memory foam (viscoelastic) polyurethane resin (PUR) is common in mattresses, upholstery and backpack padding. It is an open cell flexible foam, 30-100 kg/m3, characterised by slow recovery rate after deformation. This property is also particularly useful in hospital beds, to prevent pressure injuries in patients immobilised for long periods.
Expanded polypropylene (EPP) over-moulded with polyurethane resin (PUR). This type of direct coating, using a rubber-like PUR with texture, is used to create tactile surfaces for automotive interiors.
A shoe prototype design by Gruppo Meccaniche Luciani, 2015. The monolithic prototype was 3D printed using Stratasys PolyJet multi-material technology. Drops of photopolymer are jetted onto the build platform, then cured with UV lamps to bond layers. Support materials are dissolved or manually removed for the finished PolyJet model. Multiple different types of material can be printed simultaneously, ranging from rigid to flexible and transparent to opaque.
Nike Hyperfuse Air Max 90, featuring thermoplastic polyurethane (TPU) film welded to knitted polyethylene terephthalate (PET), polyester, upper in neon yellow.
Wellington boot by Stella McCartney for Hunter, 2019, made with Yulex rubber. The sole and upper are moulded and welded to produce a watertight boot. The stretch-sock insert is a closed-cell foam produced with natural rubber, also from Yulex. This material offers an alternative to neoprene, a synthetic rubber typically used in these types of fabrics, like wetsuits. Image Hunter.
Puma RS 100, one-piece injection moulded shoe. Two colours of ethylene vinyl acetate (EVA) are moulded, one on top of the other, to produce a seamless slip on shoe.
Established & Sons carrier bag produced from 500 micron ethylene vinyl acetate (EVA), screen printed. Designed by Made Thought, manufactured by Progress Packaging. Image Progress Packaging.
Hancock jacket made with rubber-bonded cotton. Based on the same material as the original Mackintosh coat, it is constructed from a layer of rubber sandwiched between two layers of cotton to create a durable, waterproof fabric. The seams are handmade and bonded with rubber for a 100% watertight coat. Image Hancock.
Biocomposite cork plastic composite (CPC) injection moulded from cork granules mixed with thermoplastic polyolefin elastomer (TPO). This type of composite is good for its tactile, energy absorbing and anti-sliding properties. It is used in handles, sports products and shoe soles, for example. Likewise, cork is used in wood plastic composite (WPC), in combination with polypropylene (PP) and polyethylene (PE) for outdoor and furniture applications.
Nelson Bubble Lamp, by George Nelson for Herman Miller, 1952, formed by spraying a polyvinyl chloride (PVC) mixed with a webbing agent (which causes the PVC to form filaments) onto a steel wire frame, and finished with a layer of pure PVC spray coating
Trax airport seating, by Rodney Kinsman for OMK, 1989, features a self-skinning polyurethane resin (PUR) foam upholstery, cast and powder coated aluminium arms and an extruded aluminium beam
Spot Material is a database of materials for sustainable design, curated by Rob Thompson. Compare properties, carbon and end of life, find better alternatives and discover new material innovations. Browse all materials
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