Hypercell: the new generation lightweight foam by Co.Bo.

For the past year, there has been a lot of talk in Europe about SCF (supercritical foam). I emphasise Europe because SCF has already been used in the Far East for several years. Inherited from the automotive industry, it is a manufacturing process that allows the production of expanded materials that retain their thermoplastic properties. To tell the truth, there is no single type of production process, but the common denominator of all processes that go under the name SCF is that the thermoplastic material in a fluid state is mixed at high temperatures (and pressures) with a gas in its ‘supercritical’ state, i.e. a particular physical state in which the gas resembles a fluid without actually being one. As the temperature and pressure decrease, the gas returns to its gaseous state, forming microbubbles that remain trapped inside the material. The big difference between SCF and EVA is that the ‘contained’ microbubbles do not require the ‘container’ material to cross-link (i.e. its molecular structure to form covalent bonds that make the material thermosetting) in order to remain trapped, and therefore the material remains, to all intents and purposes, a thermoplastic that can be returned to a fluid state by heating.

Co.Bo., an Italian company that has been manufacturing highly innovative soles for 40 years, will present Hypercell to the footwear industry, a technology that is definitely worth keeping an eye on because it has what it takes to compete with many of the materials currently used in both the performance footwear and luxury sneaker segments.

Compared to EVA, it achieves densities of less than 0.2 g/cm3 while maintaining the elastic rebound characteristics typical of polyurethane products and offers superior dimensional control in the moulding process compared to foams.

Compared to TPU, it offers the lightness typical of foams without compromising abrasion resistance.

Compared to PU with TPU film, both because the design can be much cleaner and because it easily exceeds 100,000 flex cycles.

And also compared to SCF, which has recently appeared in Europe, because it is completely free of the typical marbling streaks, also ensuring the possibility of homogeneous colours without compromise.


Matteo Pasca
Arsutoria School director


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TECHNICAL FEATURES

Density: 0,15 – 0,20 gr/cm3

Hardness: 45 – 48 Asker C

Flexural strength: > 100.000 cycles

Energy return: > 50%

Abrasion resistance: <= 160 Gr/mm3

Compression resistance: < 30%

Split Tear strength: 3.5 mm (20 mm)


TECH PROPERTIES AND ADVANTAGES

Enhanced Durability: +60%
Engineered for resilience, Hypercell resists wear and tear, significantly extending the lifespan of high-performance footwear products.

Extremely Lightweight: -30%
Hypercell reduces overall product weight by 30% compared to traditional injected EVA materials, enhancing performance and efficiency without compromising structural integrity.

High Energy Return: +70%
Hypercell provides exceptional energy rebound, boosting responsiveness and performance while reducing wearer fatigue. 


APPLICATIONS

Midsole
Hypercell midsoles applications offer optimal comfort, energy return, and durability, making them ideal for high-performance sports footwear and technical running shoes. Engineered for athletic performance, it is suitable also for safety and lifestyle applications.

Single-mold
The Single Mold application allows for a seamless, one-piece product construction, improving durability and reducing assembly time. Perfect for casual sneakers, lifestyle shoes, and slip-ons where lightweight comfort and streamlined design are essential.

Insert
Designed to complement existing midsole structures, Hypercell midsole insert applications provide targeted comfort and energy rebound in specific areas. Ideal for technical footwear, including trail running and hiking/safety shoes, where additional support and responsiveness are needed.

Filler
Hypercell midsole filler applications optimize material usage by filling voids within the sole structure, reducing weight without compromising strength. Commonly used in performance footwear and fashion sneakers to balance lightweight design with structural integrity.