Name: SoftCore
Availability: OutOfStock

Product Introduction

SoftCore is a recyclable thermoplastic flexible elastomer that offers excellent soft wrapping comfort while maintaining outstanding shape stability during wear. It is especially suitable for applications that require both flexibility and comfort, and has been uniquely applied in yoga footwear and dance shoes.

In footwear manufacturing, SoftCore is mainly used as a toe puff stabilizer and a flexible heel protection piece. According to different flexibility and elasticity requirements, various grades can be selected for different toe-puff applications, making SoftCore an ideal choice for flexible toe reinforcement.

Highlights

As a flexible product series, SoftCore is an important part of CAYO’s toe-puff material portfolio. It features:

High elasticity and easy formability
Under 120–150°C thermoplastic processing conditions, and according to the SATRA TM83 test method, the material achieves around 85% shape retention even after 50 destructive test cycles
It has been adopted by numerous brands and used in over 500 million pairs of shoes as a toe reinforcement material

This high-flex, high-resilience toe puff material is a preferred reinforcement solution for sports footwear, and is suitable for a wide range of shoe types.

Product Categories

This high-performance flexible thermoplastic elastomer series is designed to meet the needs of footwear that pursue long-lasting elastic shape in the toe area. Depending on the requirements of each shoe style, brands can select from different elasticity grades to achieve the desired performance match.

Average recycled content: 20%

Standard thicknesses:
0.8 mm, 1.0 mm, 1.2 mm, 1.5 mm, 1.8 mm, 2.0 mm

Standard size:
1 m × 1.5 m

Product code:
VGAOL

Material Composition

SoftCore is composed of:

Polyester fibers
Ethyl acetate-based blends
Polyurethane TPU
POE (polyolefin elastomer)

Heel Shaping Specifications

Process Parameter Guidelines

Heat Activation Process (Heat Mold / Hot Air)

Working Temperature: 130°C to 160°C
Pressing Time: 25-40 seconds (depending on equipment model, working conditions, and upper/lining material)
Interface Temperature: Measured temperature between the heel and upper: 80°C-100°C

Cold Shaping Process

Working Temperature: 5°C or lower
Pressing Time: 25-40 seconds (depending on equipment model, working conditions, and upper/lining material)
Interface Temperature: Measured temperature between the heel and upper: Must be below 40°C

Note: The lower the temperature of the component after cold shaping, the better the final shaping effect.

Cutting

The SoftCore products should be cut transversely along the widest width of the material. Multi-layer cutting is supported, with the number of layers depending on the material grade and the cutting equipment used.

Thinning (Slitting)

Slitting should be done on the reverse side of the material (opposite to the side facing up during cutting). To achieve the best results, it is recommended to use a rotary blade slitting machine and apply silicone-based lubricant or cool down the blade to prevent the blade from sticking to the material.

Pre-Lamination

Medium-temperature series products can be laminated with heel linings using appropriate lamination equipment. The use of hot melt adhesive for the lining provides the best results.

Pre-Shaping

To facilitate embedding and positioning, medium-temperature series products can be pre-formed, but the material must first be heated to 50°C-60°C. This temperature range allows the material to soften appropriately for shaping, while preventing premature activation of the hot melt adhesive, which could make the operation difficult.

Embedding Specifications

In the footwear manufacturing process, the CAYO team recommends sewing the edges of the heel part naturally to the upper. Using solvent-based adhesives to fix the heel position may negatively affect adhesive strength and shaping effectiveness.

Heel Molding

To achieve the best activation effect, it is recommended to use a heel molding machine equipped with a heated inner mold and airbag pressure device. Silicone pressure devices are also suitable.
For the best molding results, cold molds must be used. It is recommended to use cold molds at below 5°C combined with an airbag pressure device for cold shaping.

Toe Puff / Toe Cap Shaping Specifications

Heat Press Machine Parameter Settings

Heating Top Plate Temperature: 120°C - 160°C (depending on equipment model, working conditions, and upper/lining material)
Interface Temperature (measured temperature between the heel and upper): 90°C - 120°C
Constant Pressure: 4.20 - 6.0 BAR (kgf/cm²)
Pressing Time: 15-20 seconds

Sample Production Requirements

When using the adhesive edge bonding process, the shape of the toe cap component must closely fit the contour of the upper's edge.
When using hot-melt bonding, ensure the toe cap is positioned 8-10mm back from the edge of the upper’s edge. This ensures that, after the upper edge is bonded, the maximum range of the upper's edge can directly contact the insole.

Hot-Melt Bonding Process

Depending on the structure of the upper and the assembly process, either a curved press machine or a flat press machine should be used for processing.
The curved press hot-melt machine helps form a three-dimensional shape, making the upper edge bonding process easier to handle.
Note that a conveyor belt-type laminating machine cannot apply enough pressure on the toe cap, which will significantly reduce the effective bonding rate between the toe cap and the upper.

Last Shaping

The SoftCore achieves optimal processing results when used on a heel molding machine equipped with a preheating device and cold molds.
When the material is applied in the following manner:

Embedded in a pocket sewn onto the last or stitched upper structure (e.g., strong edge bonding process),
ensure that the material is thoroughly activated before edge bonding and it is recommended to undergo thermal shaping.

Storage and Transportation Conditions

Store in a cool environment (< 25°C) and dry conditions (humidity < 60%). Avoid direct sunlight during storage.

In summer, avoid transportation under direct midday sunlight at around 40°C.
The temperature inside the transport container must not exceed 60°C.
Stacking height should be no more than 2.5 meters.
During hot seasons, it is safer to arrange transportation at night whenever possible.