The EcoComfort® Revolution

A Closer Look at INSITE® Open Cell PU Footwear Foams

From the racing flats that carry athletes across the finish line, to the sneakers that keep workers on their feet for long shifts, there is one foam the footwear industry has relied on for decades to provide breathable, lightweight cushioning. Open cell PU foam insoles have been a mainstay for delivering all-day comfort, at an affordable price point that helps brands keep costs lower for their customers.

But even tried-and-true materials need to shake things up now and then. INSITE EcoComfort^® open cell PU foams introduce new levels of performance and durability. And as a bonus, we’ve partnered with bio-based suppliers to dramatically reduce the use of fossil fuel in our open cell PU production—without sacrificing the quality that traditional open cell PU is known for.

What is Open Cell PU?

In a nutshell, open cell polyurethane (PU) foam has two features that make it ideal for insole cushioning: 

• Polyurethane is a plastic with rubber-like qualities, supplying shoes with a layer of durability and shock absorption with varying levels of energy return.
• Having an open cell structure means the material consists of tiny bubbles with open cell walls. This often makes the foam a bit lighter than closed cell materials, and it gives the foam a breathable, sponge-like feel. 

Since its commercial debut over 70 years ago, open cell PU foam has been found in mattresses, medical supplies, athletic equipment and, of course, footwear. According to the Polyurethane Foam Association, there are over “1.5 billion pounds of foam produced and used every year in the US alone.” Wherever you find comfort, there’s a good chance you’ll find an open cell PU foam.

What Makes EcoComfort Open Cell PU Stand Out?

Given how open cell PU foam can make you feel like you’re walking on air, it’s easy to see why so much footwear uses it for their insoles. But what makes EcoComfort stand out above the rest?

1. It’s more durable. We’ve gone above and beyond to give EcoComfort foams a compression set that stands up to rigorous ASTM testing, so you can enjoy better cushioning benefits for longer.
2. It’s more versatile. EcoComfort foams can be made with a wide variety of softness, density, and energy return properties. From casual sneakers to work boots to everything in between, if you’ve got a comfort need, we’ve got an EcoComfort foam for the job.
3. It’s more sustainable. Customers value a quality footwear product, but they also care about their environment. EcoComfort foams mean you don’t have to choose between them. We make EcoComfort foams with up to 50% Susterra® Bio-PDO, derived from industrial field corn instead of fossil fuels. This means foam with the same quality, lower carbon emissions, and zero compromises on comfort or performance.

Ready for the Revolution?

It’s time to embrace the change! INSITE EcoComfort open cell PU foams have better compression sets, a wide range of cushioning properties, and bio-based options that take performance to the next level. Best of all, there are lot of ways to roll EcoComfort foams into your footwear for long-lasting, breathable cushioning:

• Compression molded or die-cut insoles
• Dual density layers on poured PU insoles
• Strobel boards for your footwear construction
• Rolled goods for your existing die-cut process

Whatever plans you have for your next footwear design, EcoComfort foams take the already versatile open cell PU to the next level.