Synthetic upper (PU synthetic leather)
See also: Textiles, Leather and Nonwovens · Mobility · Consumer Goods and Appliances
What it is
Polyurethane synthetic leather (also called PU leather, synthetic leather, vegan leather in marketing contexts) is a composite material consisting of a base fabric (typically polyester or polyester/cotton nonwoven) coated with one or more polyurethane layers. The manufacturing process can be via coating or lamination, with different technological variations to achieve different aesthetic and functional properties.
The surface PU layer is what gives the material its leather-like appearance — textured, pigmented, with matte, glossy or metallic finish as desired. Properties of flexibility, abrasion resistance, water resistance and durability come from the combination between PU type, its thickness and finishing treatments. Premium formulations include poromeric PU — with microcellular porous structure that simulates the breathability of natural leather.
In the footwear context, synthetic leather is used in a large portion of casual, sports, safety and fashion footwear in mid-market and entry-level pricing. Natural leather remains dominant in premium segments, but growing environmental and animal welfare pressures are pushing even premium brands toward high-quality synthetic alternatives (Stella McCartney, Veja, Allbirds as notable examples).
Why it matters
For footwear manufacturers, the choice between natural and synthetic leather (and within synthetic, the quality level) defines product market positioning. Footwear with low-quality synthetic ages badly — peels, tears, loses color — generating consumer dissatisfaction and brand reputation damage. High-quality synthetics can last years with excellent appearance, effectively competing with natural leather in perceived durability.
There is an ongoing revolution in the synthetic leather industry, driven by three forces: sustainability (growing pressure for lower-environmental-impact materials), animal welfare (younger consumers increasingly vegetarian/vegan) and technological innovation (new waterborne and bio-based PUs with increasingly better performance). Brands that position themselves well in this context gain share in premium segments.
For the automotive market, PU synthetic leather is a growing alternative to natural leather in interiors, driven by cost, consistency and environmental pressure. Audi, BMW, Mercedes, Tesla use high-quality synthetics in different lines.
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Related applications
Microcellular casual footwear sole
Bicomponent microcellular PU system · Dual density PU system
Sports midsole (E-TPU and microcellular PU)
E-TPU (Expanded Thermoplastic Polyurethane) — BASF Infinergy · High-performance microcellular PU
Anatomical insole
Molded HR flexible foam · Molded viscoelastic foam
Safety footwear soles (PPE)
Dual-density PU system · Antistatic PU