When it comes to underfoot comfort, few materials are as proven and versatile as polyurethane (PU) foam. It can be uniquely engineered for just the right levels of breathability, shape support, and impact protection. Plus its durable, wear-tested cushioning properties bring exceptional long-term value to footwear components like insoles and midsoles.
However PU is sometimes dense or heavier than other types of shoe foams. And in the world of footwear development, every fraction of a gram counts. Developers might love the nuanced benefits of PU, but they often opt for cushioning materials with less weight — even when it means sacrificing quality and user experience.
Fortunately the INSITE innovation team has developed a new generation of lightweight PU materials, so you never have to choose between performance and light weight. These foams use techniques like high-heat molding and new plant-based compounds to achieve the extraordinary comfort, performance, and support of PU — at a lower density than ever.
Let’s take a look at each foam — and find out how you can integrate them into your next line of footwear.
The most revolutionary PU in the new INSITE lineup, Levation™ IF103 offers game-changing performance to athletic footwear in a way that legacy PU formulas never could.
Levation™ uses an advanced PU formula and high-heat molding process to deliver lightweight energy return similar to EVA — but with the long-term durability and compression set of poured PU.
The result is a high rebound foam that goes the distance and gets your customers airborne, offering PU cushioning benefits with almost 25% less density than a foam with the same physical properties.
Several years ago we introduced our groundbreaking range of EcoComfort® PU foams made with Susterra® propanediol. Made from sustainably grown U.S. dent corn, Susterra® replaces a percentage of petroleum-based compounds, significantly reducing carbon emissions and improving foam durability.
With EcoComfort® Terrain IF99, we continue to innovate on that poured PU formula, now with a total of 50% eco-friendly plant-based compounds. In addition to Susterra®, this blend introduces Nuvolve®, an enzymatic biomaterial made with E.U. grown beet sugar. Nuvolve acts as a high performance additive, lowering foam density while providing improved chemical structure, so it’s easier to engineer than ever.
EcoComfort® Terrain IF99 poured PU foam offers durable comfort, shape support, and impact protection ideal for work wear, tactical, and outdoor gear.
Open cell PU is one of the easiest ways to add a layer of breathable cushioning to any line of footwear. EcoComfort® Stratus IF98 features a blend of 50% plant-based compounds — making it one of the highest bio-content open cell PU foams on the market.
Just like its poured PU counterpart, EcoComfort® Stratus IF98 open cell PU features a blend of both Susterra® and Nuvolve® to help it achieve lower density, greater compression set, and higher sustainability. It can also be used in dual density applications with poured PU, adding breezy soft cushioning on top of durable, form-fitting shock absorption.
Ready to redefine gravity for your footwear customers? Request a tech pack from INSITE today, and we’ll send you samples of INSITE’s latest foam innovations.
Last month we sat down with INSITE Biomechanics Research Lab Assistant Lily Bartel to discuss her research as she completes her master’s degree at Oregon State University and how it relates to her work with INSITE.
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