Shaping the next generation of performance footwear

For years, Dow and Under Armour have been collaborating behind-the-scenes to disrupt the status quo and deliver breakthrough innovations within the athletic shoe space. The first brainchild, born in 2018, was UA HOVR™, UA’s third generation foam cushioning for running shoes that married incredible comfort and high energy return.

Once again, in 2019, Dow and UA changed the game with another disruptive shoe technology. This almost magical technology for sole structures that could prevent slipping, deliver durability, comfort and responsiveness without bulk.

During one of their routine innovation days, Dow approached UA with a pioneering concept – rubber-less “unitsole” shoes that were lightweight and could deliver unprecedented stability and flexibility. Initially, this unitsole technology was designed for UA’s running shoes, but after testing prototypes in the gym of UA’s Portland campus with four-time NBA champion Stephen Curry, a new application was dreamed up - basketball shoes. The challenge then became mastering the unique specifications of the material in time to be launched as the inaugural product within the Curry Brand.

Historically, shoe midsoles are formed of several components with rubber outsoles which requires a more complex manufacturing process and more weight to achieve ideal performance. Together, a hand-selected team of engineers from Dow and UA worked for three years to develop UA Flow – also known by UA as “unicorn foam”- the industry’s first “unitsole” foam material that eliminates the need for rubber outsoles.

Anytime you’re introducing a game-changing technology like this, the bumps are hard to avoid. For example, during wear testing, key foam performance issues were identified. But, by playing so well together, Dow was able to seamlessly conduct foam cell morphology studies using proprietary lab technology, identify root cause and recommend new processes to help UA maintain a successful, on-time delivery. Teamwork makes the dream work, right?

Performance is key, but so is being good stewards of the planet. That’s why this collaboration was about more than just the physical performance of the shoe. The “unicorn” foam helped UA lower the carbon footprint of its manufacturing process by reducing materials, energy, waste and labor required. Additionally, the cost-savings potential is substantial; the technology can reduce cycle time required to assemble the shoe sole by 50%.