Graphene-enhanced bio-based polymers for cushioning and thermal comfort in footwear
Versarien's proprietary graphene-infused polymer technology enhances mechanical, thermal, and damping properties of thermoplastic elastomers used in athletic footwear midsoles and outsoles. The technology enables lighter, stronger, more durable shoes with improved energy return, abrasion resistance, and thermal comfort, and is being extended to bio-based polymer grades for greater sustainability.
Overview
Versarien has developed a proprietary graphene additive technology that significantly enhances the performance of thermoplastic elastomers used in athletic footwear, particularly in midsoles and outsoles. By incorporating very low loadings of graphene into polymers such as PEBA (Pebax), TPU, and EVA, the technology delivers improvements in strength, stiffness, elongation, and abrasion resistance while also optimizing mechanical damping behavior for enhanced cushioning and thermal comfort. The company is now extending this proven technology into bio-based polymer grades, such as Pebax RNew, to offer a more sustainable solution for performance footwear manufacturers seeking lighter, stronger, and longer-lasting products.
Technical specifications
Key features and demonstrated benefits:
- Mechanical reinforcement: Graphene addition promotes microphase separation in TPEs at very low loadings, increasing stiffness, toughness, and strength without compromising structural integrity.
- Lightweighting potential: Enhanced mechanical properties allow for lighter shoe designs, contributing to improved running economy and maintained initial hardness.
- Optimized damping: Graphene shifts the material's damping behavior to an optimal temperature range, maximizing mechanical damping for better cushioning.
- Abrasion resistance: Improved abrasion resistance extends product lifespan.
- Thermal comfort: Enhanced heat dissipation improves thermal comfort during prolonged use.
- Processing efficiency: Faster processing cycles in both TPU and PEBA polymers reduce energy consumption during manufacturing.
- Minimal cost impact: Negligible impact on overall production costs.
Validated performance data:
- Graphene-reinforced TPU: strength up to 124%, stiffness up to 30%, elongation up to 15%, abrasion resistance up to 24%.
- Even at 0.1 wt.% loading in Pebax: stiffness 14%, strength 34%, elongation 61%, abrasion resistance 8%.
Technology readiness level
The graphene-enhanced polymer technology has been validated in commercial applications. Versarien has already partnered with Flux Footwear (USA) to launch footwear products featuring graphene-infused rubber outsoles, and the technology has been demonstrated in both TPU and Pebax grades (7033 hard and 3533 soft). The current proposal aims to extend the technology into bio-based Pebax RNew grades through a structured three-work-package development program over approximately six months, culminating in real-life shoe prototype testing focused on cushioning and thermal comfort. This positions the technology at an advanced stage, ready for co-development and pilot integration with footwear brand supply chains.
About Versarien
Versarien plc is an intellectual property-led advanced engineering materials group that develops and manufactures innovative solutions based on proprietary technology. The group operates through multiple subsidiaries that specialize in the production and application of advanced materials, including graphene and tungsten carbide. By leveraging scientific research and its internal manufacturing capabilities, Versarien aims to transform intellectual property into commercially viable engineering products. The company focuses on expanding its material portfolio, establishing licensing arrangements, and acquiring companies that align with its goal of commercializing advanced materials technology across diverse industrial sectors.
These material solutions are designed to address specific technological and engineering challenges faced by modern manufacturers, offering potential improvements in areas such as energy storage and industrial application performance. Through its subsidiaries, Versarien provides industry sectors with graphene-enhanced products and other engineered nanomaterials. The group maintains a focus on verification and quality standards, having been the first company to achieve the Verified Graphene Producer certification. By providing working capital, plant, and operational expertise, the company works to integrate these advanced materials into existing industrial supply chains, solving material-related problems for its customers and partners.
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