Description
nora® Lunatec Fusion 30 is a lightweight, flexible expanded EVA sheet developed for orthotic and prosthetic fabrication using adhesive-free fusion bonding technology. With a hardness of approximately 30 Shore A and a density of around 0.15 g/cm³, this material offers an ideal balance of cushioning, stability, and elastic recovery, making it suitable for multilayer orthotic builds, insoles, and comfort components where reliable bonding and dimensional stability are required.
As part of the Lunatec Fusion system, the material can be permanently bonded to other Lunatec Fusion layers without adhesive. When heated and processed under pressure, the EVA surfaces fuse together during cooling, creating a strong, durable bond without glue, solvents, or intermediate layers. This allows faster production, cleaner workflows, and more environmentally friendly processing.
Material specification
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Hardness: approx. 30 Shore A
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Density: approx. 0.15 g/cm³
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Surface: smooth or perforated
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Sheet format: approx. 1000 × 700 mm (39.4" × 27.5")
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Edges: trimmed for accurate processing
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Thermoforming temperature: approx. 130°C (266°F)
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Bonding: fusion bonding without adhesive within the Lunatec Fusion range
Available versions
Smooth
Perforated
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Colour: 378 blue
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Thickness: 4 mm
Intended applications
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Orthotic insoles and footbeds
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Multi-layer EVA constructions
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Cushioning and comfort layers
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Stabilising layers in orthoses
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Lightweight midsole builds
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Sandwich constructions without adhesive
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CAD/CAM and manual fabrication workflows
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Diabetic and sensitive foot applications
Key properties
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Lightweight and flexible EVA
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Good elastic recovery
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Dimensionally stable
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Reliable cushioning performance
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Fusion bonding without glue
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Clean and fast workshop processing
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No discoloration from adhesive
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Strong bond after cooling
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Suitable for deep drawing and vacuum forming
Fusion bonding principle
The Lunatec Fusion range uses the natural bonding properties of EVA polymer to create permanent bonds between layers without adhesive. When heated to the recommended temperature and pressed together, the materials fuse during the cooling phase, forming a bond that can be stronger than the material itself. This process is similar to hot-melt bonding but requires no additional glue or intermediate layer.
Processing instructions
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Roughen all bonding surfaces before heating
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Use perforated material where possible for optimal bonding
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Oven setting: approx. 130°C / 266°F
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Follow recommended heating times
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Apply sufficient pressure during vacuum forming
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Rule of thumb: heating time × 2 = ideal cooling time
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Perforated sheets heat faster and may reduce heating time
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Cooling time depends on total material thickness
Advantages of fusion processing
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No adhesive required
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Reduced fabrication time
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Clean and healthy working environment
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No solvent fumes or glue contamination
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No drying or waiting time
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Immediate use after cooling
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Strong, permanent bond
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Environmentally friendly production
nora® Lunatec Fusion 30 is ideal for orthotic, prosthetic, and orthopaedic footwear workshops looking for a modern EVA material that combines comfort, stability, and efficient adhesive-free processing within the Lunatec Fusion system.
