Introduction Few materials have swept the global athletic footwear market as rapidly as E-TPU (Expanded Thermoplastic Polyurethane). Known for its iconic "popcorn-like" appearance and revolutionary underfoot feel, E-TPU combines the high durability of traditional TPU with the superior elasticity of high-performance foams, defining a new gold standard for modern athletic comfort.
Core Features: Thousands of Tiny Energy Capsules
The nickname "popcorn" perfectly illustrates the physical foaming process: TPU granules are expanded 5 to 10 times their original size, creating oval-shaped microspheres filled with tiny, sealed air cells.
Every single E-TPU bead acts like an independent micro-air spring. When thousands of these beads are fused together, they provide exceptional shock absorption and an energy return rate of 60%-70%. Crucially, E-TPU maintains its mechanical properties in extreme temperatures; unlike traditional EVA, which hardens in the cold, E-TPU remains soft and responsive even at -20°C.
Aybroad’s Manufacturing Edge: Steam Chest Molding
The engineering challenge of E-TPU lies in bonding independent beads securely without collapsing their delicate internal air cells. Aybroad utilizes advanced Steam Chest Molding technology:
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Precision Thermal Fusion: By precisely controlling the pressure and penetration time of high-temperature steam, we melt only the outer "skin" of each bead to create a strong bond, preserving the core’s structural integrity.
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Structural Consistency: Our process results in insoles and midsoles with superior bond strength and high grain definition, ensuring the material won't delaminate or lose its signature "bouncy" feel over time.
Applications & Customization
E-TPU is the primary choice for premium running shoes and comfort walking footwear. Beyond the classic white, Aybroad offers Multi-Color E-TPU molding capabilities, providing brands with broader aesthetic possibilities without compromising performance.