Shanghai, China — As running continues to expand worldwide and performance-driven training increasingly blends into everyday use, expectations for running footwear are rising. The midsole, once regarded mainly as a cushioning component, is now expected to function as a system that delivers performance, manufacturing reliability, and sustainability at scale.

Lubrizol today announced the release of its latest white paper, “Material Power, Performance Acceleration: Building a New Industrial Ecosystem for TPU Physical Foaming.” The paper examines how thermoplastic polyurethane (TPU) physical foaming is redefining midsole design and manufacturing, and why system-level collaboration is becoming essential for next-generation footwear platforms.

As the inventor of TPU, Lubrizol draws on its global material expertise and long-standing industry experience to analyze the structural challenges facing midsole development. These challenges include rising performance demands, increasing pressure for manufacturing efficiency, and the need for consistent, scalable production across regions. The white paper outlines how TPU physical foaming addresses the inherent limitations of traditional EVA chemical foaming, enabling manufacturers to achieve both advanced performance and high-quality industrialization.

Rather than viewing innovation through a single technology lens, the white paper introduces a dual-track development framework. Autoclave embryo foaming and supercritical injection foaming are presented as complementary approaches—one focused on unlocking performance potentials, the other on improving production efficiency and automation. Together, they support globally scalable, multi-tier midsole platforms capable of meeting diverse market needs.

“Running shoe midsoles are under a fundamental shift,” said Lu Zhang, Vice President of Lubrizol, “Competition is no longer about isolated performance metrics. It’s increasingly shaped by how effective materials, processes, and manufacturing systems work together to deliver a consistent experience. This white paper is intended to serve as a reference framework - not only for technology selection, but for how the industry can move toward a more collaborative and resilient ecosystem.”

From the consumer perspective, runners are looking beyond initial sensations such as lightweight feel or rebound. Long-term durability, consistency over time, and confidence that products will perform reliably across different markets and production batches are becoming equally important. The white paper identifies TPU physical foaming as a key enabler for globalized production models that balance performance with manufacturing stability.

“TPU physical foaming represents a meaningful step forward for this industry,” said Justin Park, Global Footwear Market Director at Lubrizol. “It delivers improvements in performance and comfort while also supporting more consistent, efficient, and repeatable manufacturing. As brands scale globally, this balance is no longer optional—it is accelerating.”

The white paper also emphasizes that successful industrialization requires the integration of materials, processes, and equipment—signaling a broader shift from linear supply chains toward collaborative innovation models that invite closer partnership across the value chain, with the goal of delivering a more consistent end-user experience.

Lubrizol continues to invest in both material and process innovation to accelerate the industrialization of TPU physical foaming, with the opening of its Foam Center of Excellence (CoE) in Shanghai, building on its existing CoE footprint in Korea. These facilities connect Lubrizol’s global R&D capabilities with regional application expertise, enabling closer collaboration with processors, equipment partners, and brands to accelerate commercialization.

Through sustained investment and open collaboration, Lubrizol is advancing the evolution of running shoe midsoles—supporting improved performance, consistency, and sustainability while helping to shape the next phase of the footwear industry’s transformation.

Lubrizol Releases White Paper on TPU Physical Foaming