What Makes a Shoe Durable?

Do a quick search of user reviews on any footwear website, and you’ll find that one of the greatest predictors of a one-star review is how durable the shoe is. Whether it’s an outsole coming unglued, stitches loosening, or (our biggest pet peeve!) the cushioning flattening out, nobody wants to buy a shoe that falls apart with a little wear and tear.

Brands typically develop shoes on a six-month seasonal cycle. But that doesn’t mean customers are only wearing those shoes for half the year before they retire them. In fact, footwear consumers are more price-conscious than ever, and as such they want a shoe with materials that will go the distance.

The challenge, of course, for shoe developers is that price and quality often go hand-in-hand. So, how do you build a durable shoe your customers can depend on for months at a time – without breaking your budget, or theirs?

Why Durability Matters

We understand it’s tempting to cut corners when it comes to the long-term durability of footwear materials. But at INSITE, we believe you shouldn’t have to. There are lots of affordable options that can give your products the performance they need – and the quality your customers deserve.

When you make shoe durability a priority, you’re investing in the success of your footwear line:

1. It’s better for your brand. When you go the extra mile to ensure your customer’s long-term comfort, you’re building a reputation for dependable products. Customers swear by the shoes that stick with them on rugged treks and lengthy workdays. And when the time comes for a second pair, they’ll remember that your brand was with them through thick and thin.
2. It’s better for sustainability. There are a lot of possibilities when it comes to making products that are better for the environment – from recycled materials that give shoe components a second life, to bio-based foams that reduce fossil fuel dependence. But durability can add another sustainable factor: the longer shoes stay on your customers’ feet, the longer they stay out of the waste management cycle. Shoes that are still on feet are shoes that aren’t buried in landfills.
3. It’s better for your customer’s foot health. Worn-out shoe components are more than just cosmetic. They can have a seriously negative effect on how a customer feels in their shoes. An unglued outsole becomes a tripping hazard. Loose stitching creates irritation and instability. And flattened-out cushioning means worse outcomes for joint load and plantar pressure.

It’s obvious there’s a strong case for making shoes more durable. That begs the question: what materials should you be using to do it? There’s a huge catalog of possibilities for uppers and outsoles, but since we here at INSITE specialize in cushioning, we’ll just focus on what makes insoles and midsoles better for the long-term.

What Makes Durable Cushioning?

At INSITE, we supply cushioning systems that help brands make better shoes through biomechanics. And nothing affects your body’s comfort and movement like unreliable cushioning. Here are a few things you should look for if you want to build cushioning that’s in it for the long haul.

1. Compression set – Compression sets measure how much the foam flattens out over time. This is indicated by what percentage of thickness is lost under certain test conditions. The lower the percentage, the longer your foam is likely to maintain its cushioning after repeated wear.
2. Tear strength, elongation, and tensile strength – The usual twists and turns of the foot can expose footwear cushioning to stretching and potential tearing. It’s important to know how much of these forces your foam can withstand, so it’s not breaking apart under the usual mechanics of footwear.
3. Water resistance – Many foam materials can break down over time due to water exposure. Having an impermeable membrane or a breathable open cell structure can help maintain the integrity of the foam by keeping sweat and moisture out.

What’s the Most Durable Foam?

Lots of chemistries can give your footwear cushioning the integrity it needs for enduring comfort. However, for the most durability you can get from your insole or midsole foams, INSITE recommends poured polyurethane (PU).  It has some of the lowest compression sets on the market, and it can be engineered for a wide range of cushioning properties to suit nearly any shoe category.

INSITE Levation™ poured PU foams range from shock-absorbing support for work boots – to plush, luxurious comfort for dress shoes and lifestyle sneakers. New formulas like our Levation™ Rebound 0.20D insole foam introduce higher energy return and lighter weight, easily replacing EVA for categories like tactical, trail running, and field sports. Best of all, Levation foams can be made with up to 70% bio-content like Susterra® Bio-PDO™ – without compromising performance and durability.

Build Shoes Like You Mean Business

Every footwear brand wants loyal customers, but loyalty has to be earned. When you invest in the long-term durability of your shoe materials, you’re sending a message of commitment to your customers’ lifelong foot health. As you plan your next footwear design, consider the cushioning foams that will give them the comfort, performance, and support they need – year in, year out.