Covestro has introduced a new series of thermoplastic polyurethane (TPU) materials called Desmopan® FLY. These materials are designed specifically for use with supercritical fluid (SCF) foaming, a process that helps create lightweight products with high performance. The new TPU range aims to meet the rising demand for sustainable, durable, and comfortable materials, especially in footwear, but also in sports gear, furniture, and electronics.
Desmopan® FLY is formulated to work well with SCF technology, producing foam with a fine, even structure. This leads to products—like shoe midsoles—that offer better cushioning, improved energy return, and long-lasting comfort.
Because the material doesn’t require chemical blowing agents or crosslinking agents, the resulting products are recyclable. When used with soft TPU outsoles, the entire shoe sole can support recycling and circular design goals.
“Sports brands are looking for materials that perform at a high level while also being better for the environment,” said Wilson Chan, who leads TPU business development for Covestro in Asia Pacific. “Desmopan® FLY delivers the durability and lightness they need, and it works well with automated manufacturing, helping brands build recyclable shoes more efficiently.”
Covestro has also installed an advanced SCF injection system at its research center in Taiwan. This facility allows Covestro to support product development and testing in-house, working closely with companies that want to explore SCF-compatible TPU applications.
“This new system shows our ongoing focus on improving TPU materials and manufacturing,” said Dr Christian Haessler, who leads global innovation in TPU at Covestro. “Having this setup in our R&D center means we can fine-tune both the material and the foaming process to help customers move faster from idea to production.”
Combining Desmopan® FLY with SCF foaming allows for more energy-efficient manufacturing and helps reduce carbon emissions. The injection process also integrates several parts into one step, which speeds up production and ensures consistent quality.
Desmopan® FLY is now available for commercial use, backed by Covestro’s technical support and production capabilities. The goal is to give sports and lifestyle brands better tools for creating high-performance products that are easier to recycle and more efficient to make.
Covestro is a global manufacturer of high-performance plastic materials used in transportation, construction, electronics, healthcare, and consumer products. The company is focused on building a circular economy and aims to reach climate neutrality for its own operations by 2035, and across its entire supply chain by 2050. Covestro had €14.2 billion in sales in 2024 and operates 46 production sites worldwide, employing around 17,500 people.
