Lucerne, 3 October 2017. Sekisui Alveo, European manufacturer of high-quality polymeric foams, has just introduced a new product with unique touch and feel properties. Being very soft, and with high resilience and longterm elasticity, Alveolux XRE cushions and holds its shape very well – and this, in combination with its good hygienic and anti-slip properties, makes the new foam a first choice for applications in the orthopaedic and shoe industries.

Although the new foam performs like rubber, it is entirely different. Advantages in processing and softer cushioning open a much wider range of application opportunities. Because Alveolux XRE has a very fine closed-cell structure, skived surfaces are neat and clean. The material can be formed several times, e.g. to adapt to the specific anatomical shape. Rubber and PU cannot be reworked in this way.

Ideal for orthopaedic applications
Sascha Paul, Application Development Manager at Sekisui Alveo responsible for Alveolux XRE, says the initial feedback regarding orthopaedic applications in the test phase has been positive: “The performance characteristics of the material, the workability, the light weight, and the high quality make Alveolux XRE a serious contender for quickly becoming the first choice in several different orthopaedic applications.”

Mechanical requirements for orthopaedic cushioning materials
Orthopaedic materials must not only be soft and provide good cushioning for high comfort, they must provide various degrees of hardness and stiffness for proper support. With unique shear strength and resilience properties, Alveolux XRE provides excellent performance in this regard. Compression set behaviour is good compared with other materials with similar softness and density. This good performance is long-lasting, as there is nearly no embrittling over the time as seen with PU foams.

Certified hygienic
The main hygienic requirements for insoles and orthopaedic devices are twofold: nontoxicity and resistance to fungus and bacterial growth. Alveolux XRE is ISO 10993 compliant, meaning it is biocompatible – and it is also washable. It is OEKO-TEX compliant, latex free, and contains no heavy metals. Alveolux XRE is also resistant to sweat and moisture. The material is approved for Class I medical devices (EEC directives 93 and 42) such as orthopaedic insoles, orthotic paddings, and bandages.

Ideal thermoforming properties
Converting with Alveolux XRE is easy and efficient. The formula has been optimised for thermoplastic conversion, and in this process it performs as well as other Alveolux foams, with very good compression set. Excellent thermoforming behaviour at lower temperatures leads to faster processing, saving energy and costs. With forming time up to three times faster than other foams on the market, at 150°C Alveolux XRE 07 requires just one minute in the oven and three minutes in press-forming – and it retains its softness after thermoforming. Other processing benefits include the high stretching ratio in thermal conversion and the option for laminating the foam with other materials.

Outstanding technical properties
Alveolux XRE shows good tensile strength, very good tensile elongation and very low Shore A hardness – in fact, the lowest in the Alveolux product range. Alveolux XRE is available in various densities to perfectly suit the specific application, from 110 - 330 kg/m3 , corresponding to Shore A hardness from 14 - 25.

Unique and innovative foam for demanding applications
Alveolux XRE is made in the EU and is being launched on the market this autumn. This unique and innovative foam also offers strong potential in the fields of seals and packaging.