#Textile chemistry

2021-04-15

3D-printed TPU insoles

Materials manufacturer Covestro and orthopedic service provider GeBioM mbH, based in Münster, Germany, are expanding their cooperation in the field of orthopedic footwear. In addition to producing lasts and trial shoes, they now support orthopedic shoemakers in the production of custom insoles using 3D printing.

More sustainable production of individual productsA new Addigy® FPU 79A thermoplastic polyurethane (TPU) from Covestro is used in the form of filaments. Together with Danish printer partner Create it REAL, the companies offer a novel and sustainable solution for the digital production of shoe insoles.

"Our new TPU plastic and a printer developed specifically for this application make it possible to print very soft structures. The material and printer were harmonized during development to achieve a perfect result," explains Lukas Breuers, 3D printing expert at Covestro. "With the help of the automated software solution, soft and hard structures can be combined in a shoe insole, achieving a level of customization that was previously virtually impossible." The TPU also meets the requirements for medical devices with regard to cytotoxicity and skin sensitization in accordance with the DIN EN ISO 10993-5 and 10993-10 standards.

In addition to functionality, the development of the material also focused on its ecological footprint, as Marcel Domenghino, Managing Director of GeBioM, points out: "It was important to us that the new solution also allows for improved sustainability. Currently, the production of insoles also generates large amounts of waste. Moreover, the insoles themselves are hazardous waste after use. With 3D printing, we now enable our customers to produce in a waste-free manner by using only the material that is needed for the insoles."

Aiming for recyclable material

Covestro is currently working on a recyclable TPU for this application and is developing opportunities with GeBioM and value chain partners to recover used insoles for recycling. Already, the spools on which the filament is wound are reused. The development is part of a global strategic program to fully align the company with the Circular Economy. Components of the program include innovative recycling technologies and the increased use of alternative raw materials such as biomass, CO2 and plastic waste, as well as renewable energy.

Covestro and orthopedic service provider GeBioM are now also supporting orthopedic shoemakers in the production of customized insoles using 3D printing. Covestro's thermoplastic polyurethane Addigy® FPU 79A is used in the process. © GeBioM

Covestro has been committed to developing innovative material solutions for additive manufacturing products for years and offers a versatile product range under the Addigy® brand, including for orthopedic shoe insoles. Just recently, the company also significantly strengthened its 3D-printing portfolio with the acquisition of the Resins & Functional Materials business of the Dutch DSM Group.

Covestro, FILK Freiberg, and OUT e.V. develop flexible, conductive polymer smart textile system

As the smart textiles market continues to grow across healthcare, personal protection, sportswear, and automotive applications, developers are seeking new ways to integrate electronic functionality directly into textiles, without the rigidity and complexity of conventional wiring. To address this challenge, FILK Freiberg Institute, an independent research institution with expertise in polymer coatings for textile applications, collaborated with Optotransmitter-Umweltschutz-Technologie (OUT) e.V. The joint project, funded under the German Industrielle Gemeinschaftsforschung (IGF) program of the Bundesministerium für Wirtschaft und Energie (BMWE), focused on developing flexible, conductive polymer surfaces for next-generation smart textiles.

Covestro to exhibit solutions for a more sustainable and productive textile industry at Techtextil 2026

Covestro will present a broad portfolio of material innovations for textile coatings, adhesive films and thermoplastic polyurethanes (TPUs) at Techtextil 2026 (Hall 11.0, Booth C79). The exhibits will demonstrate how advanced solutions can enhance durability, recyclability and manufacturing efficiency across applications such as automotive, infrastructure, protective apparel and sportswear. A particular focus will be on more sustainable coating technologies, including antimicrobial systems based on INSQIN® in combination with AGXX from Heraeus Precious Metals, as well as the integration of Pontacol® thermoplastic adhesive films into Covestro’s offering.

Covestro showcases monomaterial concept in autonomous SUE People Mover

UE | STUDIOS has unveiled the fully autonomous electric minibus “Self-driving Urban E-Shuttle” (SUE), placing strong emphasis on sustainable material design. Developed within a project funded by the Federal Ministry for Economic Affairs and Energy (BMWE) and the European Union, the vehicle will begin public road testing this year. At the core of the concept is the consistent use of recyclable monomaterials to improve circularity at end of life.

Covestro and Heraeus Precious Metals collaborate to enable safer, more sustainable antimicrobial textile coatings

Laboratory tests reveal that AGXX antimicrobial surface technology from Heraeus Precious Metals is fully compatible with Impranil® PU dispersions which are part of the waterborne INSQIN® textile coating technology from Covestro, paving the way for more sustainable antimicrobial textile coatings. This discovery comes at a key moment for the textile coatings industry. As the sharing economy continues to grow, more people are coming into regular contact with high-use surfaces, creating ideal conditions for bacteria, viruses, and other microorganisms to thrive.

SOKO presents low-impact denim finishing innovations at Denim PV Milan

SOKO will present a range of sustainable denim finishing technologies and collaborative projects at the upcoming Denim Première Vision Milan on 20–21 May in Milan. At booth G27 in Superstudio Più, the company will showcase new chemical solutions designed to combine fashionable denim effects with reduced environmental impact.

2026 general meeting of the Friends and Supporters of RWTH Aachen at ITA

The Friends and Supporters of RWTH Aachen e. V. (proRWTH) looked back on a successful year of support at their 2026 general meeting. The meeting took place at Institut für Textiltechnik (ITA) of RWTH Aachen and was combined with a joint session of the Executive Board and the Administrative Board. Before the general meeting began, participants were given a guided tour of ITA, providing them with fascinating insights into current research and development topics in textile engineering.

Cotton ConneXions Insight to Impact brings supply chain leaders together around cotton innovation

Cotton Incorporated’s Cotton ConneXions Insight to Impact brought together more than 300 industry leaders from 140 companies across 10 countries, including more than 45 top global brands and sourcing organizations, underscoring strong global interest in cotton-rich product development, sourcing and supply chain collaboration.

Footwear innovation enabled by warp knitting technology– insights from New Balance

The future of the athletic shoe is increasingly being shaped on warp knitting machines. For KARL MAYER, the footwear industry is one of the most important growth markets – and one of the sectors where innovative textiles can realize their full potential. In his keynote address at the opening of KARL MAYER’s TEXTILE INNOVATION CENTER in Obertshausen in April, Vishnu Prakash Muthusamy, Senior Textile and Materials Engineer at New Balance, explained the opportunities that warp knitting technology opens up for performance, sustainability, and faster development processes, and why textile manufacturers are transitioning from suppliers to development partners.