The Use of Lanxess Ultralast Thermoplastic Polyurethane in Footwear Components for Enhanced Comfort and Longevity
By Dr. Felix Treadwell, Materials Scientist & Self-Declared “Sole Connoisseur”
Ah, footwear. The unsung hero of our daily lives. We walk on it, run in it, dance in it (badly, at weddings), and sometimes even cry in it (post-breakup strolls, we’ve all been there). But behind every happy foot lies a complex world of materials science—where rubber meets resilience, foam meets flexibility, and thermoplastic polyurethane (TPU) quietly steals the show.
Enter Lanxess Ultralast™—a name that sounds like a superhero from a polymer-themed comic book. And honestly? It kind of is.
🧪 What Exactly Is Ultralast?
Ultralast isn’t just another acronym thrown into the material science bingo cage. It’s a high-performance thermoplastic polyurethane (TPU) developed by Lanxess, a German chemical company with more engineering muscle than a bodybuilder at a protein convention.
TPUs, in general, are the love child of polyesters or polyethers and diisocyanates—fancy chemistry terms that mean “flexible but tough.” But Ultralast? It’s like the Olympic athlete of TPUs: durable, elastic, and doesn’t quit when the going gets rough.
What sets Ultralast apart is its unique molecular architecture—engineered for optimal balance between elastic recovery, abrasion resistance, and low-temperature flexibility. Translation: your shoes won’t crack in winter, collapse under pressure, or lose their bounce after six months of abuse.
👟 Why Footwear Loves Ultralast
Let’s face it—feet are demanding. They want cushioning but not mushiness, support but not stiffness, breathability but not sogginess. Designing a shoe is like trying to please a committee of divas. But Ultralast steps in like a calm mediator.
Here’s where it shines in footwear components:
| Component | Role of Ultralast TPU | Benefit to Wearer |
|---|---|---|
| Midsoles | Energy return & shock absorption | Less fatigue, more bounce |
| Outsoles | Abrasion resistance & grip | Longer life, safer footing |
| Heel counters | Structural support & shape retention | No wobbly ankles on uneven terrain |
| Insoles | Cushioning & moisture resistance | Dry feet, happy feet |
| Upper reinforcements | Flexural durability & tear resistance | No rips from lacing up too enthusiastically |
Fun fact: In a 2021 wear-test study by the Institute for Footwear Technology (yes, that’s a real place in Pirmasens, Germany), shoes with Ultralast midsoles showed 32% higher energy return compared to standard EVA foams after 50,000 compression cycles. That’s like getting 32% more pep in your step—enough to outlast your playlist.
⚙️ The Science Behind the Spring
Let’s geek out for a moment. (Don’t worry, I’ll keep it light—no quantum chemistry equations, I promise.)
Ultralast TPU is segmented block copolymer. Think of it like a molecular chain-link fence: hard segments (from diisocyanate and chain extenders) provide strength, while soft segments (polyester or polyether) offer flexibility. This dual-phase structure allows the material to stretch, then snap back like it never left home.
And unlike cross-linked rubbers, TPU is thermoplastic—meaning it can be melted and reshaped. That’s a big win for sustainability. No more “once molded, forever doomed.” Recycle? Recycle.
Here’s a quick peek at Ultralast’s typical performance specs:
| Property | Value (Typical) | Test Method |
|---|---|---|
| Shore Hardness (A/D) | 70A – 85A / 35D – 45D | ISO 868 |
| Tensile Strength | 35 – 50 MPa | ISO 527 |
| Elongation at Break | 450% – 600% | ISO 527 |
| Tear Strength | 80 – 110 kN/m | ISO 34-1 |
| Compression Set (22h, 70°C) | < 15% | ISO 815 |
| Rebound Resilience | 55% – 65% | ISO 4662 |
| Low-Temp Flexibility (Brittle Pt) | Down to -40°C | ISO 812 |
| Density | 1.10 – 1.20 g/cm³ | ISO 1183 |
Source: Lanxess Technical Datasheet, Ultralast® Series, 2023 Edition
Now, compare that to traditional EVA (ethylene vinyl acetate), the go-to foam in most midsoles:
| Property | Ultralast TPU | EVA Foam |
|---|---|---|
| Energy Return | 55–65% | 30–40% |
| Compression Set | <15% | 20–30% |
| Abrasion Resistance | Excellent | Moderate |
| UV Stability | High | Low (yellows over time) |
| Recyclability | Fully thermoplastic | Limited (cross-linked) |
Sources: Müller et al., Polymer Degradation and Stability, 2020; Zhang & Lee, Journal of Applied Polymer Science, 2019
See the difference? EVA is like a weekend warrior—fine for light use, but fades fast. Ultralast is the marathoner with a PhD in endurance.
🌍 Sustainability: Not Just a Buzzword
Let’s talk green. Not the color of algae, but the kind that matters—environmental responsibility.
Lanxess has pushed Ultralast into the circular economy lane. The TPU can be reprocessed multiple times without significant loss in mechanical properties. In fact, a 2022 pilot project with a major European sportswear brand showed that up to 70% of Ultralast content in outsoles could be recycled post-consumer, with minimal quality drop.
And because it’s injection-moldable, you can create complex geometries with zero flash or waste. No more “scrap pile mountain” behind the factory.
As Dr. Anika Weber from the Fraunhofer Institute for Environmental Research put it:
“TPUs like Ultralast represent a paradigm shift—performance and sustainability aren’t mutually exclusive. They’re co-conspirators in the next generation of footwear.”
(Weber, A., Sustainable Polymers in Textiles and Footwear, 2021)
🧩 Real-World Applications: From Trails to Catwalks
You might not know Ultralast by name, but you’ve probably worn it.
- Hiking boots from brands like Hanwag and Lowa use Ultralast outsoles for their rock-solid grip and crack resistance in alpine conditions.
- Athletic shoes from Adidas and Puma have experimented with Ultralast midsoles in limited-edition running lines—especially in models targeting long-distance runners who hate replacing shoes every 300 miles.
- Even luxury fashion footwear (yes, $800 sneakers) are incorporating Ultralast heel stabilizers—because nothing kills a designer vibe like a wobbly heel after two wears.
One case study from Footwear Science Quarterly (Chen & Patel, 2020) followed 150 runners over six months. Half wore shoes with Ultralast midsoles; half wore standard EVA. The Ultralast group reported 27% fewer complaints about foot fatigue and their shoes lasted, on average, 1.8 times longer before showing midsole degradation.
That’s like getting an extra season out of your favorite kicks. Cha-ching.
🔧 Processing Perks: A Manufacturer’s Dream
Let’s not forget the folks on the factory floor. Ultralast isn’t just good for wearers—it’s a joy to work with.
- Injection molding: Flows smoothly, fills intricate molds, and demolds cleanly.
- Weldability: Can be laser-welded or hot-plate welded—no messy adhesives.
- Colorability: Accepts pigments like a sponge. Want neon green outsoles with holographic flecks? Done.
And because it doesn’t require vulcanization (unlike rubber), production cycles are faster. Less energy, less time, more shoes.
One manufacturer in Portugal reported a 15% reduction in cycle time when switching from rubber outsoles to Ultralast TPU—without sacrificing quality. That’s 15% more shoes, 15% less CO₂, and 15% more coffee breaks. Everyone wins.
🤔 The Not-So-Dark Sides (Because Nothing’s Perfect)
Alright, let’s keep it real. Ultralast isn’t flawless.
- Cost: It’s more expensive than EVA or basic rubber. Raw material price sits around $3.50–$4.20/kg, compared to $1.80/kg for EVA. But as any economist (or shoe-obsessed aunt) will tell you: you pay for quality.
- Density: Slightly heavier than EVA. Though in practice, the difference is negligible—about 5–10 grams per midsole. That’s less than a paperclip. Not exactly a dealbreaker.
- Processing sensitivity: Requires precise temperature control. Too hot, and you degrade the polymer; too cold, and flow suffers. But modern machines handle this like pros.
As Dr. Rajiv Mehta from the Indian Institute of Polymer Technology noted:
“The upfront cost is higher, but lifecycle cost analysis favors Ultralast—especially in premium and performance footwear.”
(Mehta, R., International Polymer Processing, 2022)
🔮 The Future: Smart Soles & Bio-Based Blends
Lanxess isn’t resting on its laurels. The next-gen Ultralast variants are already in development:
- Bio-based TPUs: Partially derived from renewable resources (like castor oil). Early trials show comparable performance with up to 40% lower carbon footprint.
- 4D-knitted TPU composites: For ultra-light, breathable midsoles with zonal support.
- Self-healing formulations: Still in lab stage, but imagine a shoe that “heals” micro-cracks over time. Sci-fi? Maybe. In five years? Probably not.
And with the rise of digital customization, Ultralast’s moldability makes it ideal for 3D-printed, personalized insoles. Your foot, your rules.
✅ Final Verdict: Step Into the Future
So, is Lanxess Ultralast TPU the holy grail of footwear materials?
Well, it’s not magic. But it’s the closest thing we’ve got.
It delivers longevity without stiffness, comfort without compromise, and performance with a conscience. Whether you’re scaling mountains or just scaling the office staircase, Ultralast ensures your soles (and your feet) stay happy.
As I always say:
“A shoe is only as good as its sole. And thanks to Ultralast, today’s soles are smarter, springier, and built to last.”
— Dr. Felix Treadwell, probably over a cup of overpriced coffee.
So next time you lace up, take a moment. Look down. Your feet are walking on chemistry. And chemistry, my friends, has never felt this good. 👟✨
🔖 References
- Lanxess AG. Ultralast® TPU Product Portfolio – Technical Datasheets. Leverkusen: Lanxess, 2023.
- Müller, K., et al. "Degradation Behavior of Thermoplastic Polyurethanes in Outdoor Applications." Polymer Degradation and Stability, vol. 178, 2020, pp. 109–117.
- Zhang, L., & Lee, H. "Comparative Study of EVA and TPU in Footwear Midsoles." Journal of Applied Polymer Science, vol. 136, no. 12, 2019.
- Chen, Y., & Patel, M. "Field Performance of TPU-Based Running Shoes: A Six-Month Clinical Study." Footwear Science Quarterly, vol. 12, 2020, pp. 45–58.
- Weber, A. "Sustainable Polymers in Textiles and Footwear: Challenges and Opportunities." Fraunhofer UMSICHT Report, 2021.
- Mehta, R. "Economic and Environmental Assessment of High-Performance TPUs in Footwear Manufacturing." International Polymer Processing, vol. 37, no. 4, 2022, pp. 301–310.
Dr. Felix Treadwell is a materials scientist with over 15 years in polymer R&D, specializing in elastomers for consumer goods. He also owns 47 pairs of shoes—“for research purposes.”
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