How to propel polyurethane footwear formulas forward
Athletic footwear consumers demand performance and sustainability. Innovation is a must to avoid losing customers to the competition. With the market poised to hit $119 billion in 2025, brands can step up to the challenge to meet consumers鈥� evolving needs.1
Several factors contribute to the market鈥檚 predicted compound annual growth rate of 3.12% from 2025 to 2030.2
- Athleisure: Consumers want convenient footwear that can go from walks to workouts3
- Income: Increasing disposable income influences willingness to buy premium footwear4
- Lifestyle: More Europeans invest in active lifestyles for wellbeing5
- Sustainability: Sustainable footwear demand is increasing in countries like Spain, Germany, France, and the 麻豆传媒6 7
The polyurethane (PU) soles market is also growing, worth $5.5 billion in 2023, and by 2030, it鈥檚 predicted to be worth $10.1 billion.8
Emerging trends and technologies reshape polyurethane footwear formulation and provide innovation paths for manufacturers.
Keep pace with consumer-preferred athletic footwear qualities
Staying current on consumer athletic footwear needs can influence formula and ingredient decisions.
Three must-have qualities consumers want in athletic shoes:
1. Maximal cushioning
2. Durability
Consumers want more than comfortable athletic shoes; they also need them to last, especially when they鈥檙e multi-purpose. Longevity applies to all shoe parts, from the outsoles to the inside cushioning.
3. Breathability
Step into the future of technology-powered footwear innovation
Various technological innovations impact footwear formulas and can help manufacturers stand out.
3D printing is leaving its impression on the footwear industry, offering more personalisation and faster iterations.
Brands combine AI and 3D printing to develop personalised footwear. By leveraging AI to create designs and 3D printing, brands can offer more customised solutions.
Technology like this can help manufacturers:
- Streamline the research process
- Lower manufacturing costs
- Reduce production time
- Achieve formulation flexibility
- Create more consistent products
Take the pathway to develop more sustainable footwear
Regulatory and consumer demand for sustainable footwear continues to grow. The footwear market experienced a 15% year-over-year demand increase for 鈥渆co-friendly footwear." 12
Even with cost-of-living and inflationary concerns, consumers would pay 9.7% more for sustainably produced or sourced goods.13
To meet demand, footwear companies are shifting towards eco-friendly materials, such as:
- Recycled plastics
- Natural fibres
- Bio-based polyurethane
Create innovative, high-performing polyurethane footwear with Shell CARADOL庐 polyols
Shell CARADOL can help propel shoe and sole performance and innovation forward. With production capabilities across Europe and availability in various molecular weights, Shell CARADOL can meet application needs for athletic shoe adhesive formulation and flexible foam polyurethane footwear.
Our scientists continually refine our products and offer industry-leading expertise to customers formulating with Shell CARADOL. Application labs support our customers with:
- Product technical information
- HSSE information
- Quality and testing support
- Start-up and training support
- Formulation support
Whether you want to enhance comfort or increase product lifespan, Shell CARADOL delivers the flexibility and durability manufacturers need.
Athletic shoe adhesive formulations with Shell CARADOL are:
Fast curing
|
Low-temperature performance |
| Flexible | Viscosity |
| Strong | Solvent-free |
| Thermally strong | Solvent-based/containing |
| Tuneable | Reactive 鈥� hot melt |
| Bonding/glueing | Green strength |
| Waterproofing | Tailor-made/bespoke solutions |
| Weathering |
Foam shoes formulated with Shell CARADOL offer durability, support, and more:
| Flexible conventional Slabstock | Viscoelastic slabstock | |
| Continuous production | X | X |
| Durability | X | X |
| Porous/open cell | X | X |
| Support | X | X |
| Maintains shape over time | X | X |
| Low resilience | X | X |
| Breathability | X | X |
| Strength | X | X |
| Amine-free | X | X |
| Low-VOC | X | X |
| Porosity | X | X |
| Wider processing spectrum | X | X |
| High-quality yield | X | X |
| Co-polymers/SAN | X | X |
| Performance | X | X |
As athletic footwear becomes more personalised, sustainable, and high-performing, innovation will define the next generation of product leaders. Shell CARADOL enables manufacturers to translate market pressures into durable, scalable advancements that meet evolving consumer demands without compromising performance.
Speak with an expert today about polyols for foams and adhesives:
Sources:
1 https://www.statista.com/outlook/cmo/footwear/europe
2 https://www.statista.com/outlook/cmo/footwear/europe
3 https://www.imarcgroup.com/europe-footwear-market
4 https://www.imarcgroup.com/europe-footwear-market
5 https://www.imarcgroup.com/europe-footwear-market
6 https://www.statista.com/outlook/cmo/footwear/europe
7 https://market.us/report/sustainable-footwear-market/
8 https://www.elastomer.kuraray.com/blog/polyurethane-soles/
9 https://www.globenewswire.com/news-release/2025/02/18/3028115/0/en/Athletic-Footwear-Market-to-Hit-Valuation-of-US-247-51-Billion-by-2033-Astute-Analytica.html
10 https://www.rockyfootandankle.com/faqs/how-much-do-feet-sweat-in-1-day-click-to-find-out-now.cfm
11 https://www.rockyfootandankle.com/faqs/how-much-do-feet-sweat-in-1-day-click-to-find-out-now.cfm
12 https://www.globenewswire.com/news-release/2025/02/18/3028115/0/en/Athletic-Footwear-Market-to-Hit-Valuation-of-US-247-51-Billion-by-2033-Astute-Analytica.html
13 https://www.pwc.com/gx/en/news-room/press-releases/2024/pwc-2024-voice-of-consumer-survey.html