DuPont Mobility & Materials has introduced a new closed-cell elastomer foam produced via a supercritical fluid (SCF) foaming process. The fully recyclable material is said to be the first foamed product in the company’s Hytrel range of copolyester-based thermoplastics elastomers.

Unlike foamed materials that rely on chemical foaming agents, the elastomer foam is produced using CO2 and N2 gases in the SCF process. The process leaves no residues from chemical foaming agents in the final products, and emits no VOCs, stated DuPont, adding that end products are free of odours and allergens.

DuPont listed property advantages for the expanded material as including up to 15% greater resilience than TPU foam (up to 80% resilience vs. 65% for TPU foam).

The foam, it added, has a density 0.10-0.16 g/cm3 (up to 20% lighter than EVA, and more durable) and hardness 30-45 Shore C (10 points higher than expanded TPU).

Target applications include footwear, sporting goods, consumer goods, furniture, and wire and cable jacketing, according to the materials company.

Brand owners “are looking for more sustainable materials and production methods to counter climate change,” said Hilary Wang, marketing manager at DuPont Mobility & Materials.

 “These companies are also actively seeking a more sustainable process than chemical foaming, which is being restricted or even phased out in some countries,” added Wang.

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