Covestro: A Step Forward in Lightweight Innovation
Covestro continues to lead the way in customer-centric material solutions. With the launch of Desmopan® FLY, a cutting-edge Thermoplastic Polyurethane (TPU) series, the company pushes the boundaries of supercritical fluid (SCF) injection foaming. This innovation supports customer needs for lighter, stronger, and more sustainable products—especially in footwear, sports gear, furniture, and electronics.
By installing an in-house SCF foaming system at its Taiwan R&D facility, Covestro not only enhances material capabilities but also strengthens its support for application development across the Asia-Pacific region.
What is SCF Injection Foaming?
Supercritical fluid injection foaming is a process that introduces supercritical CO₂ or nitrogen into polymer melts. As a result, it forms fine-cellular foam structures with consistent quality and excellent mechanical properties. Unlike traditional foaming, it avoids chemical blowing agents, making the process cleaner and more sustainable.
Why Desmopan® FLY Stands Out
Desmopan® FLY is not just another TPU. It has been specifically engineered for SCF foaming, offering a combination of:
- Superior fluid dispersion during molding
- Uniform fine-cell structure for better cushioning
- Outstanding energy return and durability
- Full recyclability due to the absence of crosslinking additives
In footwear, these features create long-lasting midsoles with high performance. Additionally, when paired with a soft TPU outsole, brands can offer a fully recyclable sole system—a direct nod to circular economy goals.
Delivering What Customers Demand
Consumer preferences are changing rapidly. Today’s buyers seek products that perform better, weigh less, and leave a smaller environmental footprint. Covestro has responded directly to this demand. According to Wilson Chan, Head of Business Development TPU Asia Pacific:
“Desmopan® FLY brings exceptional lightweight and resilience properties while maintaining durability throughout the product lifecycle.”
Moreover, the TPU series allows automated injection molding, streamlining production and reducing costs. Consequently, brands can deliver eco-friendly, high-performance footwear more efficiently than ever.
Supporting Customers Through In-House Innovation
To ensure that customers get the most out of Desmopan® FLY, Covestro invested in a pioneering SCF injection foaming system. Installed at their Asia-Pacific R&D Center in Taiwan, this facility allows Covestro to:
- Test and tailor formulations to customer needs
- Accelerate application development cycles
- Ensure consistent product quality across batches
- Provide local technical support within the region
This in-house capability reflects Covestro’s commitment to customer-centric research and development.
Efficiency Meets Sustainability
The combination of Desmopan® FLY and SCF foaming results in an energy-efficient, low-emission manufacturing process. Automated injection means:
- Fewer production steps
- Lower energy consumption
- Integrated multi-component molding
- Reduced production time and cost
Because no chemical blowing agents are used, the materials are safe for recycling. Thus, manufacturers can build greener value chains while meeting performance standards.
From Concept to Commercialization
Dr. Christian Haessler, Head of Global Innovation TPU at Covestro, explains:
“This in-house capability enables us to optimize TPU material properties with precise SCF processing parameters.”
Thanks to this integration, Covestro helps brands move quickly from concept to commercial production. Customers no longer have to rely on external partners for SCF testing. Everything—material science, processing, testing, and scaling—is available under one roof.
Applications Beyond Footwear
Although Desmopan® FLY is ideal for footwear, it has wider applications. Industries already exploring this TPU solution include:
- Sports gear – for lightweight and durable equipment
- Furniture – for foamed, supportive seating structures
- Consumer electronics – for cushioned casings and components
These sectors benefit from the resilient yet recyclable properties of SCF foamed TPU. More importantly, Covestro’s proactive technical collaboration allows each customer to create unique value in their respective markets.
Commercial Availability and Support
Desmopan® FLY is now commercially available. Customers can rely on Covestro’s technical service teams, regional R&D labs, and global material expertise. This level of support ensures seamless product development and smooth integration into existing workflows.
For brands aiming to innovate sustainably and scale quickly, Desmopan® FLY provides a ready-to-deploy solution.
About Covestro: Innovating with Purpose
Covestro is a global leader in polymer solutions that enhance the quality of life. The company serves key sectors such as:
- Mobility and automotive
- Electronics and telecommunications
- Building and construction
- Sports, leisure, and health
Covestro is fully aligned with the circular economy. Its targets include:
- Climate neutrality for Scope 1 and 2 emissions by 2035
- Scope 3 neutrality by 2050
In 2024, Covestro generated EUR 14.2 billion in revenue and operated 46 production sites globally, employing approximately 17,500 people.
Conclusion: A Customer-Centric Leap Toward the Future
With Desmopan® FLY and SCF injection foaming, Covestro is not just offering a new material. It is transforming how brands develop, produce, and deliver next-generation products.
From in-house innovation centers to regionally tailored services, Covestro stands out as a partner in progress—driving both performance excellence and sustainable value.
Learn more at the Covestro Homepage.
