Covestro has introduced Desmopan FLY, a new series of high-performance thermoplastic polyurethane (TPU) designed for supercritical fluid (SCF) injection foaming. The product addresses increasing market demand for lightweight, durable and sustainable materials, particularly in the footwear industry. Desmopan FLY also expands potential applications in sporting goods, furniture and electronic products.

Engineered for enhanced SCF dispersion, Desmopan FLY enables the creation of finely structured foam cells during the molding process. The result is a uniform foam with strong mechanical properties. In footwear applications, this technology supports the development of midsoles offering superior cushioning, energy return and long-term comfort.

The formulation eliminates the need for chemical blowing agents and crosslinking additives, making the midsoles recyclable. When paired with soft TPU outsoles, this forms a sole system aligned with circular economy goals.

“Leading sports brands are pushing for materials that deliver top-tier performance with strong sustainability profiles,” said Wilson Chan, head of business development TPU Asia-Pacific at Covestro. “Desmopan FLY offers excellent lightweight resilience while maintaining shape stability and durability across the product life cycle. Its optimized processing is well-suited for automated injection molding, helping brands produce high-performance, recyclable footwear that meets evolving consumer demands.”

To support innovation, Covestro has installed an SCF injection foaming system at its Asia-Pacific TPU R&D Center in Taiwan. This advanced setup provides integrated R&D capabilities and rapid prototyping services tailored to customer needs.

“This investment marks another milestone in our continuous innovation,” said Dr. Christian Haessler, head of global innovation TPU at Covestro. “By incorporating SCF injection capabilities into our own R&D environment, we can fine-tune TPU formulations and processing parameters with greater precision. This allows us to support our customers more effectively, from initial concept to market-ready product.”

The SCF injection process combined with Desmopan FLY offers an energy-efficient production method that reduces carbon emissions. The technology enables integration of multiple components in a single manufacturing step, resulting in improved efficiency and consistent product quality.

Desmopan FLY is now commercially available, backed by Covestro’s technical expertise and in-house testing facilities. This integrated material and technology platform supports sports brands in advancing their footwear portfolios—delivering enhanced performance, recyclability and streamlined production.

Covestro ranks among the world’s top producers of high-performance polymer materials and their components. Through its innovative products, technologies and manufacturing processes, the company contributes to greater sustainability and improved quality of life across a wide range of applications. Covestro serves customers globally in key industries including mobility, construction, and electronics. Its polymers are also widely used in sectors such as sports and leisure, telecommunications, healthcare, and the chemical industry.