TPU vs. EVA Foam — Why Choosing the Right Material Matters for PillowFlow™

When you’re designing a product that supports your leg for hours on the road, the material isn’t a small detail — it defines comfort, durability, and performance. For PillowFlow™, we tested multiple materials, put prototypes through stress cycles, and compared how they behave under real-world driving conditions.

Two contenders stood out: TPU (Thermoplastic Polyurethane) and EVA Foam (Ethylene-Vinyl Acetate Foam).

Here’s the breakdown — and why we ultimately chose EVA Foam for PillowFlow™.

What Is TPU?

TPU is a flexible thermoplastic known for:

• High elasticity
• Strong abrasion resistance
• Smooth rubbery feel
• Good flexibility for straps, cases, and soft components

But here’s the issue:
TPU behaves like rubber — great for bending, not great for structural support. Under body weight, it compresses too much and doesn’t return to its exact shape consistently over long durations. For thigh support, that leads to reduced lift, uneven pressure, and fatigue over time.

What Is EVA Foam?

EVA Foam is a high-density, closed-cell material used in:

• Athletic gear
• High-end footwear
• Orthopedic products
• Shock-absorbing pads

Its key advantages:

• Incredible cushioning
• Outstanding shape retention
• Lightweight but strong
• Excellent impact absorption
• Resistant to heat and deformation

EVA is engineered for repetitive pressure — exactly what your thigh experiences during long drives.

Why PillowFlow™ Uses EVA Foam

After months of testing, EVA Foam outperformed TPU prototypes across every comfort and durability metric:

1. Better Support

EVA distributes pressure evenly, lifting the thigh without sinking. Your leg stays relaxed. Numbness decreases. Reaction time improves.

2. Superior Comfort

Its micro-cell structure provides soft compression at the surface with firm stability underneath — the sweet spot for long-drive ergonomics.

3. Long-Term Durability

EVA doesn’t flatten, warp, or collapse. Even after hundreds of hours of pressure cycles, it springs back to its original shape.

4. Heat & Weather Resistance

Car cabins get hot. TPU softens in heat. EVA stays stable and supportive.

5. Lightweight, Travel-Ready

EVA keeps PillowFlow™ ultra-light, portable, and easy to secure with the strap.

Bottom line:
TPU is great for straps, cases, flexible parts —
but EVA is the only material that delivers reliable comfort AND engineered support for long-distance driving.

That’s why PillowFlow™ proudly uses Premium Molded EVA Foam in every unit.