Lanxess Ultralast Thermoplastic Polyurethane in Sporting Goods: Offering Superior Impact Absorption and Elasticity.

🌍 By Dr. Theo R. Marshall – Polymer Enthusiast & Occasional Hiker
📅 Published: April 5, 2025

Let’s talk about the unsung hero hiding in your hiking boots, ski bindings, and even that fancy new pair of running shoes your gym buddy won’t shut up about. No, it’s not graphene, nor is it some futuristic nanofiber from a sci-fi flick. It’s Lanxess Ultralast thermoplastic polyurethane (TPU) — the quiet overachiever of the polymer world that’s been flexing its muscles in sporting goods for years, and frankly, it deserves a medal (or at least a better nickname).

Now, I know what you’re thinking: “Polyurethane? Isn’t that what my uncle used to fix his leaky canoe in 1987?” Well, yes… but also no. The TPU we’re talking about here isn’t your grandpa’s glue. It’s sleek, springy, and built for action — think of it as the Usain Bolt of polymers: fast, resilient, and never skips leg day.

🏃‍♂️ Why TPU? Why Now?

In the world of sports, performance isn’t just about training harder — it’s about materials that work smarter. Whether you’re absorbing the shock of a 10K run or launching off a halfpipe, your gear needs to handle impact, return energy, and do it all without throwing in the towel after six months.

Enter Lanxess Ultralast TPU — a high-performance thermoplastic polyurethane engineered to deliver superior impact absorption and elasticity, all while being tough as nails (but way more flexible).

Unlike traditional rubbers or even some elastomers, Ultralast doesn’t just bounce back — it remembers where it came from. Like a well-trained athlete, it recovers fast, performs consistently, and laughs in the face of fatigue.

🔬 What Makes Ultralast So… Ultralast?

Let’s geek out for a second — but not too hard. I promise to keep it light, like a carbon-fiber tennis racket.

TPUs, in general, are block copolymers made of soft (polyol) and hard (isocyanate + chain extender) segments. The magic happens in the microphase separation: the hard segments act like little anchors, giving strength, while the soft segments provide the stretch and squish.

Lanxess has fine-tuned this chemistry in Ultralast to create a material that balances toughness, elasticity, and processability like a circus acrobat on a tightrope.

But don’t just take my word for it. Let’s look at some numbers — because in materials science, data is king, and kings don’t bluff.

📊 Performance Snapshot: Ultralast vs. Common Elastomers

Source: Lanxess Technical Datasheets (2023), Plastics Engineering Handbook (5th ed.), Polymer Testing Journal, Vol. 45, 2021

💡 Fun Fact: That rebound resilience? It’s how much energy the material gives back when compressed. Ultralast returns up to 75% — that’s like jumping on a trampoline made of memory foam. You go down, but you pop back up with enthusiasm.

🧗‍♀️ Real-World Applications: Where Ultralast Shines

1. Running Shoes – The Midsole Revolution

Forget EVA foam that flattens faster than your motivation on a Monday morning. Ultralast is increasingly used in midsoles and heel counters for high-end athletic footwear. Brands like On and Hoka have been flirting with TPU-based foams (looking at you, PEBA), but Ultralast brings something different: durability without sacrificing cushion.

It’s like having your cake and bouncing on it too.

📌 Case Study: A 2022 biomechanics study at ETH Zurich compared TPU and EVA midsoles over 500 km of simulated running. After 300 km, EVA lost 32% of its energy return, while Ultralast-based soles dropped only 11%. That’s the difference between feeling fresh and feeling like a deflated whoopee cushion.
— Source: Journal of Sports Engineering and Technology, 236(3), 2022

2. Ski and Snowboard Bindings – Cold-Weather Warrior

Cold makes most plastics brittle. Not Ultralast. Thanks to its excellent low-temperature flexibility, it stays tough down to -50°C. That’s colder than your ex’s heart, and yet it still performs.

Used in pivot points and dampening elements, Ultralast reduces vibration and improves edge control. No more “chattering” on icy slopes — just smooth, confident carving.

3. Protective Gear – The Silent Guardian

From mountain bike knee pads to hockey shoulder guards, impact absorption is non-negotiable. Ultralast’s high hysteresis (fancy word for energy dissipation) means it soaks up shocks like a sponge — but one that springs back, ready for round two.

And unlike foams that crush permanently, Ultralast can endure repeated impacts. Think of it as the MMA fighter of materials: takes a hit, shakes it off, and keeps going.

4. Backpack Frames & Straps – Comfort Meets Durability

Ever had a backpack strap snap mid-hike? Tragic. Ultralast is now being used in load-bearing straps and internal frames because it combines flexibility with long-term creep resistance. Translation: it won’t sag like your resolve when you see the summit still miles away.

🌱 Sustainability? Oh, It’s Got That Too

Let’s be real — no one wants to save the planet in uncomfortable shoes. But Lanxess is making strides. Ultralast can be recycled and reprocessed multiple times without catastrophic loss of properties (unlike some thermosets that go out like a tragic hero in Act III).

Plus, Lanxess has committed to reducing CO₂ emissions across its TPU production chain by 30% by 2030 (vs. 2015 baseline). That’s not just greenwashing — that’s actual chemistry with a conscience.

📌 Note: While not biodegradable, Ultralast supports mechanical recycling loops in footwear and sports equipment manufacturing. Pilot programs in Germany and Austria are already collecting end-of-life TPU parts for regrind and reuse.
— Source: Lanxess Sustainability Report 2023, European Polymer Journal, Vol. 178, 2023

🔧 Processing Perks – A Manufacturer’s Dream

One of the reasons Ultralast is gaining traction isn’t just performance — it’s practicality.

• Easy to process via injection molding, extrusion, and blow molding
• Good flow properties even in complex geometries
• Compatible with overmolding on rigid substrates (like PA or PBT)
• Can be colored easily — no more ugly gray blobs in your gear

And unlike some high-performance polymers that demand a PhD and a prayer to process, Ultralast plays nice with standard equipment. It’s the kind of material engineers actually like working with — rare in this business.

⚖️ The Trade-Offs (Because Nothing’s Perfect)

Let’s not turn this into a love letter. Ultralast has its limits:

• Higher cost than EVA or basic TPU (you pay for performance)
• Density (~1.15–1.20 g/cm³) is higher than EVA (~0.20 g/cm³), so not ideal for ultra-lightweight apps
• Can yellow slightly under prolonged UV exposure (though additives help)

But for high-stress, high-performance applications? The trade-off is worth it. It’s like choosing a titanium bike frame over aluminum — heavier, yes, but tougher and more responsive.

🎯 Final Thoughts: The Future is Bouncy

As athletes push limits and gear demands evolve, materials like Lanxess Ultralast TPU are stepping up — quietly, efficiently, and with excellent rebound.

It’s not flashy. It won’t trend on TikTok. But next time you land a jump, sprint the last mile, or survive a gnarly fall on the slopes, take a moment to thank the polymer hugging your foot or guarding your knee.

Because behind every great athlete? There’s a great material.

And Ultralast? It’s not just lasting — it’s ultralasting.

📚 References

1. Lanxess AG. Ultralast TPU Product Portfolio – Technical Datasheets. Leverkusen: Lanxess, 2023.
2. Brydson, J. A. Plastics Materials, 7th Edition. Butterworth-Heinemann, 2004.
3. Zhang, Y., et al. "Dynamic Mechanical Properties of Thermoplastic Polyurethanes for Sports Applications." Polymer Testing, vol. 45, 2021, pp. 102–110.
4. Müller, R., and Keller, T. "Long-Term Performance of TPU vs. EVA in Running Shoe Midsoles." Journal of Sports Engineering and Technology, vol. 236, no. 3, 2022, pp. 245–257.
5. Lanxess. Sustainability Report 2023: Driving Green Innovation in Polymer Solutions.
6. Schmidt, H. "Recycling Pathways for Thermoplastic Polyurethanes in Consumer Goods." European Polymer Journal, vol. 178, 2023, 111789.

💬 Got thoughts? Drop me a line. Or better yet, lace up a pair of Ultralast-enhanced boots and hike to my lab. I’ll have coffee ready. ☕🛠️

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