Types of Shoe Fabric Lamination

When fabric layers are bonded together—often with foam, films or membranes—to create composites that enhance comfort, durability or waterproofing, the process is called lamination. In footwear, laminated fabrics appear in uppers, linings, insoles and even outsole backings, each tailored for specific performance needs.

  1. Foam-Laminated Fabrics

These combine a textile face with a thin foam layer to add cushioning, shape stability and moisture management.

  • PU Foam Lamination
    A lightweight PU foam sheet is bonded to knit or woven fabric. This creates a soft, breathable lining or sock-liner that cushions the foot and wicks moisture away from the skin.
  • EVA and PE Foam Laminations
    Closed-cell EVA or polyethylene foams are heat-laminated to fabric for midsoles and insoles. They deliver shock absorption, resilience and low water uptake.
  1. Film-Laminated Fabrics

Thermoplastic films pressed onto fabrics give uppers water resistance and abrasion protection without bulk.

  • PU, PVC and TPU Film Coatings
    Thin films of polyurethane, polyvinyl chloride or thermoplastic polyurethane bond to face fabric under heat and pressure. The result is a flexible, scuff-resistant upper that repels rain.
  • Waterproof-Breathable Membranes
    Microporous PTFE (e.g., Gore-Tex) or hydrophilic PU films are sandwiched between outer fabric and inner lining. They block liquid water yet allow vapor to escape, keeping feet dry in wet conditions.

   3. Laminate Process Variations

The choice of lamination technology affects bond strength, flexibility and production speed.

  • Hot Melt Lamination
    A thermoplastic adhesive web is placed between fabric layers and activated by heat rollers. Bonds form instantly under pressure.
  • Extrusion Lamination
    Molten polymer is extruded directly onto one fabric surface, then pressed to a second layer. Common for PVC and PE films.
  • Liquid adhesives are coated on one layer, dried, then pressed to another. This allows more open weave structures to bond uniformly.
  • Thermal (Heat) Bonding
    For nonwovens, heat-sensitive fibers (e.g., bicomponent yarns) are melted to form self-bonded layers without the need for extra adhesives.
  1. Quick Comparison Table

Laminate Type

 Core Material Bond Method Key Benefit

Typical Location

PU Foam-Laminated

 Polyurethane Hot melt/contact Soft cushioning, moisture-wicking Sock liners, linings

EVA/PE Foam-Laminated

 EVA or PE foam Heat/pressure Shock absorption, resilience

Insoles, midsoles

PU/PVC/TPU Film-Laminated

 Thermoplastic film Extrusion / hot melt Water resistance, abrasion barrier

Uppers, overlays
Membrane Laminates PTFE/PU membrane Multi-layer press Waterproof yet breathable

Hiking/outdoor uppers