nora® Lunatec Fusion 20 is a lightweight, soft, and highly elastic expanded EVA sheet designed for modern orthotic and prosthetic fabrication using adhesive-free fusion bonding technology. With a hardness of approximately 20 Shore A and a density of around 0.12 g/cm³, Lunatec Fusion provides excellent cushioning, low weight, and high elastic recovery, making it ideal for comfortable insoles, footbeds, and layered orthotic constructions.
Part of the Lunatec Fusion range, this material allows permanent bonding between EVA layers without the use of adhesive. When heated to the recommended temperature and processed under pressure, the material fuses during cooling to create a strong, durable bond without glue, solvents, or intermediate layers. This enables faster, cleaner, and more environmentally friendly workshop production.
Material specification
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Hardness: approx. 20 Shore A
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Density: approx. 0.12 g/cm³
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Surface: smooth or perforated
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Sheet format: approx. 1050 × 760 mm (41.3" × 29.9")
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Edges: trimmed for clean 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
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Colour: 60 bright grey
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Thickness: 2 | 3 | 4 mm
Perforated
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Colour: 60 bright grey
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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 layers in orthoses
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Lightweight midsole builds
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Comfort layers for diabetic and sensitive feet
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Sandwich constructions without adhesive
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CAD/CAM or manual fabrication workflows
Key properties
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Very lightweight, soft, and elastic
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Excellent elastic recovery
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Comfortable walking properties
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Low density with high durability
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Fusion bonding without glue
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No discoloration or hardening from adhesive
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Clean and healthy working environment
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Strong bond strength after cooling
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Suitable for multi-layer deep drawing
Fusion bonding principle
Lunatec Fusion materials bond directly to each other when heated and pressed, using the natural properties of EVA polymer. During the cooling phase, the warmed layers fuse permanently without adhesive or intermediate layers. Testing according to DIN EN 1392 has shown that the bond created can be stronger than the material itself.
Processing instructions
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Roughen the materials before processing
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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 materials heat faster and may reduce heating time
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Consider total material thickness when cooling
Advantages of fusion processing
nora® Lunatec Fusion 20 is ideal for orthotic, prosthetic, and orthopaedic footwear workshops looking for a modern, clean, and efficient EVA processing system that delivers high comfort, strong bonding, and reliable performance without the need for adhesives.
