Bend it like PU – Plastics in football
31.05.2024
(Updated on June 18, 2026)
The 2026 FIFA World Cup in the United States, Canada and Mexico is currently captivating millions of fans around the globe. But it is not only the players and teams that are delivering top performances between June 11 and July 19. The materials used also play a crucial role in the success of the game. From footballs and boots to stadium infrastructure, plastics have revolutionized football and have helped make the sport more dynamic, safer and more sustainable.
And here is another fun fact: Mexico, one of the host countries of the 2026 World Cup, also holds a special place in the material history of football. More on that in a moment.
From leather to plastic – the history of the football
Football matches today are much more dynamic than they used to be. Why? Because of plastic! A look at the history of football shows this:
The development of football began before the beginning of the Common Era in China with the Ts'uh-küh, in which cloth balls were filled with animal hair and feathers and tied with nets. In the Middle Ages, balls made of sewn-together leather honeycomb were used for the first time, but they were not durable enough due to their filling of animal bladders and cork shavings. In the 19th century, they were replaced by leather balls with rubber bladders. However, these balls often had uneven trajectories and absorbed water. The transition to plastics began in the 1960s.
Modern footballs are made of polyurethane (PU) and other synthetic materials. Most of them are no longer sewn, but hot-bonded using a special thermal bonding process. This makes the ball not only durable, but also highly symmetrical. These technological advances result in balls that fly more precisely, are more durable and behave consistently in different weather conditions.
The outer shell of the official match ball for the 2026 FIFA World Cup, adidas' TRIONDA Pro, consists of four thermally bonded polyurethane panels. The ball itself is made up of several material components, each serving a specific function. Its outer cover is manufactured entirely from polyurethane (PU), a material known for its excellent abrasion resistance and therefore widely used in premium sports balls. Inside, a carrier layer made of recycled polyester and viscose is combined with a layer consisting of equal parts ethylene-vinyl acetate (EVA) and ethylene propylene diene monomer (EPDM).
Polyester provides structural stability, while viscose is a cellulose-based fiber. EVA is an elastic polymer valued for its cushioning properties, whereas EPDM is used as a durable synthetic rubber. Air retention is ensured by a high-quality butyl bladder. Butyl rubber is characterized by its low air permeability, helping the ball maintain its shape and pressure over extended periods of use.
Football boots and equipment made of plastic: lightness meets performance
Footballers today are clad almost from head to toe in plastic. The versatile material is indispensable in modern football equipment. This applies to clothing, shin guards and gloves, as well as football boots. Today, these hardly contain any natural fibres or leather.
For example, the synthetic leather upper provides a better fit, increased durability and weather resistance. Synthetic composites in the sole offer lightness and flexibility, while thermoplastic polyurethane (TPU) studs provide optimal traction and stability on different pitch types.
Shin guards benefit from synthetic materials such as EVA foam and polypropylene (PP), which offer effective impact protection at a low weight and adapt flexibly to the leg. Goalkeeper gloves also utilise synthetic materials to provide better grip and protection while remaining lightweight and flexible.
Jerseys: a reliable partner thanks to plastics
Football shirts made from synthetic materials fulfil a fundamental requirement: they are warm in the cold and cool in the heat. In addition, the breathable, lightweight synthetic fibres ensure that sweat is not absorbed but released to the outside. Friction is also reduced thanks to functional clothing. It fits the body like a second skin and therefore provides optimum freedom of movement.
For the 2026 World Cup, Nike is also placing a stronger emphasis on circularity in its national team kits. For the first time, both the match kits and the accompanying elite training collection are made entirely from textile waste. This has been made possible through an advanced chemical recycling process that transforms end-of-life textiles into recycled polyester yarn. The resulting material delivers the same performance as virgin polyester and demonstrates how synthetic fibers can help keep valuable resources in the textile loop.
Exhibitors & products around recycling
Plastics are used in a wide range of applications in football stadiums. One prominent example is artificial turf. Soft fibres made of polyethylene (PE), a base layer made of polypropylene (PP) or polyurethane (PU) and a filling of sand and rubber granules enable similar playing characteristics to natural turf. In contrast to natural turf, however, artificial turf is easier to care for and much more resistant to weather conditions and intensive use.
Plastics are also used in the seats and roofing of stadiums. Materials such as polypropylene (PP), polycarbonate (PC) and PVC ensure durable, weatherproof and lightweight constructions.
Gabriel-Chemie also proves this. Together with GSM Sella and Aurora Kunststoffe, the plastics manufacturer has developed a masterbatch for post-industrial PA 66 for the production of stadium seats in 2022. The masterbatch gives the stadium seats mechanical resistance, flame retardancy and an aesthetic appearance. It also provides the necessary protection against UV rays and other aggressive weather influences. This collaboration has made it possible to produce 30,000 new stadium seats.
Plastics contribute to greater sustainability in football stadiums. One example of this is the PreZero Arena, home to TSG Hoffenheim – the first certified zero waste stadium in the German Bundesliga. A key component of the strategy is the reusable cup system. Instead of disposable cups made from polylactide (PLA), which cannot be composted or recycled, the arena has been using durable cups made from polyethylene (PE) since 2021. These can be rinsed and reused up to 400 times. This saves around half a million cups per season!
Plastics in football stadiums contribute to improved playing conditions, increased comfort and lower maintenance costs, while at the same time promoting the sustainability and efficiency of the stadium infrastructure.
Modern footballs made from synthetic materials offer better durability, control and weather resistance. Lightweight and adaptable plastics in football boots increase players' speed and stability, while protective clothing made from materials such as EVA foam offers effective impact protection. In the stadium infrastructure, artificial turf and weatherproof components made of PC and PVC ensure durability and reduced maintenance. Technological innovations such as thermal bonding and 3D printing optimise material properties and enable customised designs, while environmentally friendly plastics and recycling methods reduce the ecological footprint.
Overall, plastics are helping to make sport more sustainable and innovative. In short, plastics have significantly improved the performance of equipment and infrastructure and are playing a key role in shaping the future of football.