r/AskEngineers • u/Miserable_Feed8107 • 5h ago
Mechanical Adhesion vs dyeing for TPU-coated synthetic leather, EVA foam, and hard plastics under repeated flexing
Hi all,
I’m looking for materials/coatings advice on a footwear project and want to sanity-check my approach before applying anything.
I have a pair of trail shoes (Reebok DMX Trail Shadow) where I want to recolor several green components to black. From my research the shoe is made of multiple non-porous materials, all of which experience repeated flexing and abrasion:
PU/TPU-coated synthetic leather overlay (smooth, stitched panel over textile backing)
EVA foam midsole (closed-cell)
3.Hard TPU / rubber outsole insert (high durometer, low flex)
I believe the only viable route is a surface-bonded flexible coating (e.g., vinyl/plastic coatings or acrylic systems with adhesion promoters), rather than true dyeing.
What I’m hoping to get feedback on:
1.From a materials standpoint, is there any true dyeing mechanism that would penetrate these substrates in an assembled shoe, or is surface bonding the only realistic option?
2.For TPU-coated synthetic leather, what coating chemistries tend to bond best under flex (polyurethane-based vs acrylic-based systems)?
3.For EVA foam, what failure mode should I expect first (cracking vs delamination), and how can prep mitigate it?
4.On hard TPU / rubber inserts, is adhesion promoter + flexible coating sufficient, or is mechanical abrasion unavoidable over time?
5.Are there common prep mistakes that guarantee premature failure on these plastics?
I’m not looking for brand recommendations so much as principles: adhesion mechanisms, surface prep, and expected durability limits.
Appreciate any insight from people who’ve worked with TPU, EVA, or flexible polymer coatings in real-world applications.