Samples of a unique foamed polylactic acid (PLA) produced by Hemcell. The PLA is prepared with CO2, so that when moulded, the CO2 causes the plastic to foam and fill the cavity. This saves material, reduces weight, and offers some moulding opportunities due to the unique behaviour of foamed plastic.
Expanded foam packaging produced with Kaneka polyhydroxyalkanoates (PHA) bio-based and biodegradable polyester. The packaging is recyclable and compostable, providing an alternative to fossil-based expanded polypropylene (EPP) and expanded polystyrene (EPS).
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.
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.
Bockatech reusable 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.
Renault interior door panel made with LYB LyondelBasell polypropylene (PP) with a chemical foaming agent added to produce a foamed part. This approach helps to save 15-20% weight. The texture is designed to eliminate the need for a covering, to save cost and ensure the part can be recycled end of life.
Renault interior door panel made with LYB LyondelBasell polypropylene (PP) with a chemical foaming agent added to produce a foamed part. This approach helps to save 15-20% weight. The texture is designed to eliminate the need for a covering, to save cost and ensure the part can be recycled end of life.
Cross-section through a rotation moulded sample that illustrates an inner layer of foam, which is used to provide added stiffness without a significant increase in weight. Both materials are polyethylene (PE) and produced in the same moulding cycle: the natural (off-white) skin is moulded and once formed the yellow foaming material is added to the mould. The colour has been added to the foamed PE to highlight the separate materials.
Adidas Ultraboost running shoe, 2015, which uses expanded thermoplastic polyurethane (ETPU) in the sole. Originally developed for Puma by BASF, the eTPU sole technology was adopted by Adidas in 2013 and named Boost. The combination of softness and elasticity provide a high level of comfort and bounce. In addition to the ETPU sole, the Ultraboost shoe features a knitted polyester upper and TPU lace cage and moulded heel support.
Expanded thermoplastic polyurethane (ETPU) midsole. ETPU is known for its superior performance in footwear due to its durability and flexibility. Image Covestro.
BASF Elastopan polyurethane resin (PUR) moulded directly onto fabric. Applied in footwear and protective clothing, for example, it offer excellent physical properties like flexibility, abrasion and hydrolysis resistance, durability and low density.
BASF Elastopan polyurethane resin (PUR) moulded directly onto fabric. Applied in footwear and protective clothing, for example, it offer excellent physical properties like flexibility, abrasion and hydrolysis resistance, durability and low density.
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.
Expanded polypropylene (EPP) moulded into an injection moulded PP shell. The rigid PP outer provides a visual surface that protects the EPP from indentation and provides additional rigidity.
Looking inside a typical sun visor, which contains an injection moulded PC/ABS structure, and the cavity is filled with moulded expanded polypropylene (EPP), which provides a durable and lightweight body.
Cross-section through rotation moulded part made up of polyethylene (PE) skin and PE foam, produced in a single step. This monomaterial solution is the result of triggering the foaming reaction at a high temperature, which occurs after the skin material has already begun to form on the surface of the mould.
Selasti moulded sole made with I'm Green bio-based EVA from Braskem. The ethylene vinyl acetate (EVA) is 45% to 80% bio-based, depending on the grade. It is produced from residues of sugar cane production, based in South America. At the end of its life, it can be recycled. Image Selasti SPA.
Dansko Kane moulded clogs are made with over 50% I'm Green bio-based EVA from Braskem. The ethylene vinyl acetate (EVA) is 45% to 80% bio-based, depending on the grade. It is produced from residues of sugar cane production, based in South America. At the end of its life, it can be recycled.
Birkenstock sandals moulded in ethylene vinyl acetate (EVA) foam. Modelled on the classic cork and leather sandal, this one-piece shoe is lightweight, waterproof and washable.
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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