BASF expands collaboration in automotive interiors with TPU-based 'Melrup' technology

Chemical company BASF has announced that, building on its collaboration with Wacoal on bra cup innovation, the two companies are expanding their joint development into the automotive interior sector. The armrest concept model unveiled by the two companies showcases the potential of Wacoal's advanced fibre-based 3D manufacturing technology and BASF's material solutions, offering enhanced design freedom while focusing on lightweight and comfortable interior components.

'Melooop' is a fibre-based 3D moulding technology developed by Wacoal. This technology processes a single-material fibre using a melt-blown nonwoven method to create a three-dimensional structure. Because fibre formation and lamination occur simultaneously, complex 3D structures can be completed in a single process without the need for separate adhesives or assembling multiple layers. This integrated approach reduces manufacturing steps, simplifies production, and minimises material usage and waste, thereby reducing environmental impact compared to previous methods. It also enables a single-material design, improving recycling efficiency. Additionally, 'Melooop' allows for adjustments in thickness and material properties from the early development stage, helping to achieve the optimal balance between weight, performance, and durability essential for automotive applications.

BASF's thermoplastic polyurethane (TPU), Elastollan®, combines the processing ease typical of thermoplastics with the elastic performance of elastomers, enabling the 'Melooop' process. In particular, it supports the formation of three-dimensional fibre structures that offer both flexibility and structural stability, and enables a single-material design that simplifies product design and manufacturing.

When applied to occupant-contact surfaces such as armrests, which are in continuous contact with the body, this approach delivers excellent elastic recovery, returning to its original shape even under repeated loads. This ensures long-term dimensional stability and provides a soft touch. Furthermore, the fibre formation and bonding process offers a robust processing window, maximising the stability of the production process.

The armrest concept model, featuring Wacoal's single-material 'Melooop' technology, will be exhibited at BASF's booth (booth number 309) at the Automotive Engineering Expo Nagoya, held from 17 to 19 June 2026.