Discovering the mechanics of ultra-low density elastomeric foams in elite-level racing shoes

TL;DR

This study combines mechanical testing and machine learning to uncover the complex mechanics of ultra-low-density elastomeric foams used in elite racing shoes, enabling better modeling and simulation for performance optimization.

Contribution

It introduces a scalable, interpretable modeling approach using neural networks and sparse regression to accurately capture foam mechanics for high-performance footwear.

Findings

Foams exhibit tension-compression asymmetry and near-zero Poisson's ratio.

Both foams have similar compressive stiffness, but differ significantly in shear stiffness.

Models achieve high R2 values, enabling detailed simulations of shoe performance.

Abstract

Ultra-low-density elastomeric foams enable lightweight systems that combine high compliance with efficient energy return. In high-performance racing shoes, these foams are critical for low weight, high cushioning, and efficient energy return; yet, their constitutive behavior remains difficult to model and poorly understood. Here we integrate mechanical testing and machine learning to discover the mechanics of two ultra-low density elastomeric polymeric foams used in elite-level racing shoes. Across uniaxial tension, confined and unconfined compression, and simple shear, both foams exhibit pronounced tension-compression asymmetry, negligible lateral strains consistent with an effective Poisson's ratio close to zero, and low hysteresis indicative of an efficient energy return. Both foams provide a similar compressive stiffness (268kPa vs. 299kPa), while one foam exhibits nearly double the shear stiffness (219kPa vs. 117kPa), implying a substantially greater lateral stability at a comparable vertical energy return (83% vs. 89%). By integrating these data into constitutive neural networks, paired with sparse regression, we discover compact, interpretable single-invariant models, supplemented by mixed-invariant or principal-stretch based terms, that capture the unique signature of the foams with R2 values close to one. From a human performance perspective, these models enable finite-element and gait-level simulations of high-performance racing shoes to quantify running economy, performance enhancements, and injury risks on an individual athlete level. More broadly, this work establishes a scalable and interpretable approach for constitutive modeling of highly compressible, ultra-light elastomeric foams with applications to wearable technologies, soft robotics, and energy-efficient mobility systems.