Dual Stencil Process


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- story by MaterialDistrict

Untill the Olympics in Seoul 1988, rubber was the material mostly used for the soles of (sport) shoes. During the Olympics a new material was introduced which was lightweight and provided much better grip than rubber, even when used on a wet surface. This resulted in better performance and therefore the material became a popular choice for top runners. However, this material and its manufacturing technology were immature enough to be widely used by the general public. Geltec Co. Ltd introduced a new patented process for the mass production of the Dual Stencil Process (DSP) material, which makes it affordable to everyone.

DSP is a new generation textile with polyurethane-based projections. With the technology, the characteristics of an ordinary textile can be greatly improved.

DSP has been gradually replacing rubber sole on the athletic shoes, primarily due to design flexibility/possibilities, functional features in traction, lightweight, and anti-abrasion. It is also used on gloves and the kneepads on wet suits, as well. Besides shoes, DSP is on its way to identifying a lot of potential in other applications such as bags, accessories, stationeries, barrier-free items to prevent slippery, house ware, apparel, packing material, etc.

DSP offers great design flexibility due to the many combinations possible based on the choice of base textile (material and colour) and tailored polyurethane projections (shape and colour). The pattern can be made up of a single or multiple, isolated, independent projections.

Due to the use of much lighter base textile and isolated, independent projections, DSP is extremely lightweight and flexible, about half the weight of rubber-made sole. As mentioned earlier the anti-abrasion performance is exemplified in the use of athletic shoes.

Polyurethane-based projections, shaped out of the mold (s), could flexibly take a variety of patterns according to your design, but Geltec has a series of ready-made projections that are produced out of their own open molds shown below. Also, the projections could be coloured, placed on one layer or on two layers. The base textile could range from regular textile to synthetic leather, neoprene, Jersey, etc as long as it allows melted polyurethane to penetrate.

Material Properties