In the world of footwear, midsole materials play a critical role in defining performance. Two of the most widely used foam compounds today are EVA (Ethylene-Vinyl Acetate) and ETPU (Expanded Thermoplastic Polyurethane). Both offer cushioning and energy return—but in very different ways.
If you're developing a new shoe or refining an existing one, understanding the strengths and limitations of each material can help you make smarter, more intentional design choices.
EVA: Lightweight & Reliable
EVA has been a midsole staple for decades. It's lightweight, easy to mold, and offers solid cushioning across a wide temperature range.
Advantages of EVA:
- Lightweight with good compression and cushioning
- Affordable and widely available
- Easy to shape and customize
- Great for lifestyle and everyday athletic footwear
Limitations of EVA:
- Can lose rebound over time with heavy use
- Limited energy return compared to newer foams
- Less durable under extreme wear or weather
EVA is ideal when comfort, affordability, and production flexibility are the top priorities.
ETPU: High Rebound & Long-Term Performance
ETPU (often recognized by brands like BOOST) is a newer foam technology made from expanded TPU beads fused together through steam molding. It’s known for exceptional rebound and long-lasting cushioning.
Advantages of ETPU:
- High energy return with a responsive feel
- Superior durability and compression resistance
- Handles cold temperatures better than EVA
- Long-lasting performance with minimal breakdown
Limitations of ETPU:
- Heavier than EVA
- More expensive to produce
- Can be more complex to mold consistently
ETPU excels in performance applications, such as workwear, trail running, and shoes that require all-day rebound and support.
Choosing the Right Material
The decision between ETPU and EVA depends on your product goals:
- For lightweight lifestyle or fashion-focused footwear: EVA may be the best fit.
- For performance-driven, safety, or high-rebound applications: ETPU offers superior longevity and comfort.
At Alcmy, we work with both materials and often design multi-density midsoles that strategically combine EVA and ETPU to get the best of both worlds.
How We Use These Materials at Alcmy
Our portfolio includes EVA soles like Fatboy and Run, designed for comfort and speed, as well as high-performance ETPU products like Ultra, Zebra, and Trampoline, where rebound and durability are key.
By choosing the right compound—and pairing it with the right design—we help brands deliver comfort, innovation, and performance at every step.
