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.
The front grille for the BMW iX is produced in a cleanroom environment, since any dust would be visible through the high-gloss polyurethane (PUR) finish. Produced in an integrated process, the component consists of a functional film that is back-injection moulded with polycarbonate (PC) and then flood-coated with 2-3 mm PUR. Engel developed the production cell.
Cross-section through the detachable roof modules of the Ford Bronco. This part is made with a thermoformed thermoplastic outer layer, which is back-moulded with glass fibre and polyurethane resin (PUR), plus a Nomex honeycomb core for increased thickness (stiffness with minimal additional weight). It is manufactured by compression moulding, whereby the thermoformed polycarbonate (PC) is placed into the mould, onto which glass fibre and honeycomb are laid. A precise dose of PUR is applied by spraying on the layers and then the whole assembly is compressed in a mould and heated to cure.
Aircraft glazing consists of a combination of laminated strengthened glass and plastic, including stretched cast acrylic, polycarbonate (PC) and polyvinyl butyral (PVB) laminating film. The aluminium fuselage is coated with polyurethane resin (PUR).
VIA57 chair, by Bjarke Ingels and KiBiSi for Fritz Hansen, 2016, consists of a steel frame, overmoulded with polyurethane foam, upholstered with wool fabric. The legs are lacquered oak
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.
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.
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.
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.
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.
Hvisk handbag in Leap alternative leather. This 89% bio-based textile is made with a three-layer structure comprising a Tencel Lyocell regenerated cellulose backing fabric, apple waste natural rubber blend middle layer that is plastic-free but not 100% bio-based, and partially bio-based BASF polyurethane (PUR) coating for durability.
Vegaplac veneer substitute bio-based composite made with agricultural waste (palm fibre residue and banana fibre) mixed with bio-based polyurethane resin (bio-PUR). The PUR is based on castor oil. Made in Brazil, distributed by Bark Cloth.
The Adidas Tilt 350 pro boxing gloves feature Desserto cactus leather, which is produced using fibres extracted from the Nopal cactus (also known as the prickly pear) mixed with PU-based resin. The cacti are grown on a ranch in Mexico without chemicals or irrigation, where they are harvested and converted into fabric. Image Adidas.
NIO car seats feature BASF Haptex artificial leather made with polyurethane resin (PUR). This is the first PUR made without organic solvents, which helps to ensure higher interior air quality. 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.
An outdoor carpet, in nonwoven polypropylene (PP), with polyurethane resin (PUR) nubs on the backside to keep the fabric off the floor and so allow water to drain away.
Cross-section through an insulated pipe, made with extruded and cross-linked high density polyethylene (XLPE) filled with polyurethane resin (PUR) foam.
Echo paraglider wing, fabricated from lightweight woven nylon (PA66) top surface (Dominico D20) and polyurethane resin (PUR) coated nylon (PA66) ripstop underside (Porcher Skytex), the largest model has an area of 28.9 m2 and weighs a mere 4.7 kg.
Duromer high-pressure laminate (HPL) exterior panels by Fundermax. They are coated with a double-cured acrylic polyurethane resin for enhanced weather protection. Image Fundermax.
Gen1 Grapes T. Black trainers by Mother Earth [MoEa] sneakers brand. The upper is made with GrapeSkin synthetic leather, which is made up of 55% grape waste, 45% water-based polyurethane resin (PUR) and recycled polyethylene terephthalate (rPET), polyester, backing. Natural rubber sole with 30% recycled content. Image MoEa.
Akonite longboard features BComp AmpliTex flax fibre and carbon fibre laminated with epoxy, with a core of ash and balsa wood. Trucks are typically cast aluminium alloy A356 and the wheels polyurethane resin (PUR).
Utrecht armchair, by Gerrit Thomas Rietveld for Cassina, 1935, consists of a steel frame, polyurethane padding and blanket stitched pigmented leather upholstery.
Leap plant-based leather alternative from Beyond Leather takes apple waste and converts it into textile. Currently 89% bio-based, it is made up of a three-layer structure, with a Tencel Lyocell regenerated cellulose backing fabric, apple waste blend middle layer that is plastic-free but not 100% bio-based, and partially bio-based polyurethane coating for durability. Image Beyond Leather.
Composite automotive sandwich panel floor assembly for Zenos E10 sports car, with thermoplastic honeycomb core and carbon fibre reinforced polyurethane resin (PUR) skins, produced with spray-up compression moulding by Bright Lite Structures
Riveted and polyurethane resin (PUR) coated aluminium aircraft wing skins for lightness, combined with a stainless steel leading edge to enable de-icing.
Bang & Olufsen BEOPLAY HX headphones feature lambskin leather ear cushions, with polyurethane foam padding and a gold-colour anodised aluminium frame, using the dip and dye method.
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
Boeing 737 800, which utilises aluminium alloy 2024 in the fuselage skin, slats and flaps, 7075 in the frames, stringers and ribs, 7178 in the wing upper skin, spars and beams, 7055 in the wing lower skin. Aircraft are typically coated with an abrasion resistant polyurethane resin (PUR) paint.
Thermoformed acrylic capped acrylonitrile butadiene styrene (ABS-PMMA), over-moulded on the backside with reaction injection moulded (RIM) polyurethane resin (PUR) for added stiffness. The ABS-PMMA provides a smooth, colourful, durable and UV-resistant outer layer
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 Check your material for free →
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