Fraunhofer Introduces Programmable Monomaterial Technology to Enable Sustainable and High-Performance Athletic Footwear

© Fraunhofer CPM
The sole of copolyester elastomer is made up of many individual sheets. The functional zones are established by the structure of ribs and ridges. Each individual sheet exhibits this structure.

(IN BRIEF) Fraunhofer researchers have developed a programmable monomaterial solution for athletic shoes that combines performance, sustainability, and recyclability. Instead of using multiple materials, the new approach uses a thermoplastic copolyester elastomer structured with ribs and ridges to create different functional zones within a single material. Demonstrated in collaboration with Puma, the concept simplifies manufacturing and significantly improves recycling potential. By using polyester-based materials across both the sole and upper, the entire shoe can be more easily integrated into a circular economy. The project also introduces advanced recycling techniques, including solvent-based purification and pyrolysis, enabling recovery of high-quality materials from used products. Supported by multiple Fraunhofer institutes, the initiative aims to create a scalable platform for programmable materials that can be applied across various industries while supporting closed-loop recycling systems.

(PRESS RELEASE) MUNICH, 4-May-2026 — /EuropaWire/ — Researchers from the Fraunhofer Society have introduced an innovative approach to athletic shoe manufacturing through the development of a programmable monomaterial sole, offering a new balance between performance, sustainability, and recyclability. The breakthrough is part of the ZiProMat project, which aims to simplify material composition while enhancing functionality.

Traditionally, high-performance athletic footwear relies on multiple materials to achieve varying properties across different zones of the sole, such as cushioning in the heel, flexibility in the midfoot, and firmness in the forefoot. This complexity complicates both production and recycling processes. The Fraunhofer team has addressed this challenge by engineering a sole made entirely from a single material that can deliver multiple functional characteristics.

The solution is based on a thermoplastic copolyester elastomer, structured in layers of thin sheets. By designing precise patterns of ribs and ridges within these sheets, researchers can effectively “program” how the material behaves under mechanical stress. When stacked and fused, these structured layers create a sole with differentiated performance zones, without the need for multiple material types.

Working in collaboration with Puma, scientists from the Fraunhofer Cluster of Excellence Programmable Materials CPM demonstrated the feasibility of this concept in high-quality athletic footwear. According to Christof Hübner from the Fraunhofer Institute for Chemical Technology, the partnership combined advanced materials science with practical product development expertise, enabling the transition of the concept from research to real-world application.

The project has since expanded through collaboration with the Fraunhofer Cluster of Excellence Circular Plastics Economy, focusing on circularity and end-of-life solutions. By using polyester-based materials not only for the sole but also for the upper components of the shoe, the researchers aim to enable more efficient recycling of entire products.

Maximilian Wende from the Fraunhofer Institute for Process Engineering and Packaging highlighted that aligning material composition across the shoe opens new opportunities for integrating products into a circular resource system.

To support this goal, the research team is developing advanced recycling methods. One approach involves selective solvent-based dissolution, which removes impurities and recovers high-purity polyester. Another method uses pyrolysis to break down materials into chemical building blocks such as terephthalic acid, which can be reused in manufacturing. These processes demonstrate that high-quality recycling can be achieved even from previously complex, multi-material products.

The initiative brings together multiple Fraunhofer institutes, each contributing specialized expertise across the value chain—from material design and processing to recycling technologies and product development. This integrated approach is intended to support the creation of next-generation products that combine performance with sustainability.

Looking ahead, researchers plan to expand the functional capabilities of programmable materials and explore applications beyond athletic footwear, including work shoes and other performance products. The long-term objective is to establish a scalable technology platform that supports closed-loop recycling and reduces reliance on complex material combinations.

Media Contact:

Kristiane von Imhoff
Head of PR and Communications
Phone: +49 208 8598-1443
Email: k-messe@umsicht.fraunhofer.de

SOURCE: Fraunhofer-Gesellschaft