Gentrex one-piece foamed thermoplastic polyurethane (TPU) shoe concept from Tienkang using Mucell physical foaming technology.

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.

Cross-section through a reusable foamed cup in polypropylene (PP), manufactured using EcoCore injection moulding technology, that integrates an insulating foam between the two outer skins (MuCell microcellular foam injection). The graphics are applied using a PP in-mould label (IML), which ensures the returnable cup remains recyclable as a monomaterial at the end of its life.

Cross-section of a foam sandwich injection moulding. The white outer is virgin polypropylene (PP) and the black core is foamed recycled PP (rPP). The layers are formed by first injecting the white (the colour has been used to emphasis the technology in this case) and then injecting the black with chemical foaming agent (CO2). The black rPP forms a bubble inside the white, pushing into onto the surface of the mould. In application, the surface layer would be the same colour as the core to create a high quality visual surface. This example is a cross-section through the LimbicLife ergonomic chair seat. The process and tooling were engineering and optimised by Deckerform.