Product Introduction
SuperTough is a recyclable thermoplastic toughening material. After heat setting and curing, it transitions from a flexible, activated state to providing strong, tough support, helping to protect the ankle and Achilles tendon during wear. It is characterized by excellent shape stability and outstanding flex resistance, maintaining its structure even under repeated bending. In footwear applications, it demonstrates high toughness and flexural strength.
SuperTough is mainly used as a heel counter stabilizer that enhances toughness. According to the toughness requirements of different shoe designs, various toughness grades can be selected to build the heel support and stabilize the shape. It is a high-toughness heel counter (toe puff/heel reinforcement) material suitable for demanding applications.
Product Highlights
As a high-toughness thermoplastic material, SuperTough offers the following performance advantages after heat setting and molding:
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At low temperatures of –20°C, it can withstand 50,000 flex cycles without cracking.
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According to SATRA TM83 testing, after 20 destructive test cycles, the shape retention rate remains above 85%.
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It has been adopted by numerous brands and has been used in over 200 million pairs of shoes.
Product Categories
The SuperTough high-toughness thermoplastic heel counter series is available in three grades:
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Ultra-tough
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High-toughness
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Tough
These variants provide a reinforcement solution for footwear styles that pursue both toughness and refined performance, making SuperTough a preferred option for shoes that require resilient, durable heel support.
Material Composition
SuperTough is composed of:
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Polyester fibers and PA (polyamide) fibers
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Thermoplastic elastomeric copolymers
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Polyester-based materials
Application Range
SuperTough has been widely used by many brands in:
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Skate-style shoes / board shoes
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Badminton shoes
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Tennis shoes
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Table tennis shoes
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Golf shoes
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Ice skates
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Premium business shoes
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Road running shoes
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Safety shoes
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High-end sport-casual shoes
It has been validated in over 200 million pairs in real-world applications.
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:
VVBOD
Heel Shaping Specifications
Process Parameter Guidelines
Heat Activation Process (Heat Mold / Hot Air)
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Working Temperature: 130°C to 160°C
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Pressing Time: 25-40 seconds (depending on equipment model, working conditions, and upper/lining material)
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Interface Temperature: Measured temperature between the heel and upper: 80°C-100°C
Cold Shaping Process
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Working Temperature: 5°C or lower
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Pressing Time: 25-40 seconds (depending on equipment model, working conditions, and upper/lining material)
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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 SuperTough 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
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Heating Top Plate Temperature: 120°C - 160°C (depending on equipment model, working conditions, and upper/lining material)
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Interface Temperature (measured temperature between the heel and upper): 90°C - 120°C
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Constant Pressure: 4.20 - 6.0 BAR (kgf/cm²)
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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 SuperTough 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:
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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.
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In summer, avoid transportation under direct midday sunlight at around 40°C.
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The temperature inside the transport container must not exceed 60°C.
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Stacking height should be no more than 2.5 meters.
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During hot seasons, it is safer to arrange transportation at night whenever possible.