Description
nora® Lunatec Fusion 50 is a high density expanded EVA sheet designed for orthotic and prosthetic fabrication using adhesive free fusion bonding technology. With a hardness of approximately 50 Shore A and a density of around 0.30 g/cm³, this material provides increased stability and strength while maintaining good elasticity and shock absorption. It is suitable for structural layers, stabilising components, and multilayer orthotic constructions where firm support and reliable bonding are required.
As part of the Lunatec Fusion system, the material allows permanent bonding between layers without the need for adhesive. When heated and processed under pressure, the EVA surfaces fuse together during the cooling phase, creating a strong and durable bond without glue, solvents, or intermediate layers. This allows faster production, cleaner working conditions, and environmentally friendly fabrication.
Material specification
-
Hardness: approx. 50 Shore A
-
Density: approx. 0.30 g/cm³
-
Surface: smooth or perforated
-
Sheet format: approx. 1020 × 675 mm (40.2 inch × 26.6 inch)
-
Edges: trimmed for accurate processing
-
Thermoforming temperature: approx. 130°C (266°F)
-
Bonding: fusion bonding without adhesive within the Lunatec Fusion range
Available versions
Smooth
-
Colour: 27 light blue
-
Thickness: 8 mm, 12 mm
Perforated
-
Colour: 27 light blue
-
Thickness: 4 mm, 8 mm
Intended applications
-
Orthotic insoles and footbeds
-
Stabilising layers in orthoses
-
Multi layer EVA constructions
-
Midsole and reinforcement layers
-
Sandwich constructions without adhesive
-
Structural components in orthopaedic footwear
-
CAD CAM and manual fabrication workflows
-
High load orthotic builds
Key properties
-
High stability with good elasticity
-
Dimensionally stable under load
-
Good elastic recovery
-
Reliable cushioning performance
-
Fusion bonding without glue
-
Clean and fast workshop processing
-
No discoloration from adhesive
-
Strong bond after cooling
-
Suitable for deep drawing and vacuum forming
Fusion bonding principle
Lunatec Fusion materials bond directly to each other when heated and pressed together. During the cooling phase, the warmed EVA layers fuse permanently without adhesive or intermediate layers. Testing of peel resistance according to DIN EN 1392 has shown that the bond created can be stronger than the material itself, meaning the material may tear before the fused layers separate.
The Lunatec Fusion range was developed to allow healthy and environmentally friendly fabrication without the use of adhesive, while still allowing the option of conventional EVA bonding when required.
Processing instructions
-
Roughen all bonding surfaces before heating
-
Use perforated material where possible for optimal bonding
-
Oven setting: approx. 130°C / 266°F
-
Follow recommended heating times
-
Apply sufficient pressure during vacuum forming
-
Rule of thumb: heating time multiplied by two equals ideal cooling time
-
Perforated sheets heat faster and may reduce heating time
-
Cooling time depends on total material thickness
Advantages of fusion processing
-
No adhesive required
-
Reduced fabrication time
-
Clean working environment
-
No solvent fumes
-
No glue contamination
-
No drying time
-
Immediate use after cooling
-
Strong permanent bond
-
Environmentally friendly production
nora® Lunatec Fusion 50 is ideal for orthotic, prosthetic, and orthopaedic footwear workshops that require a firm EVA material with strong bonding capability, good elastic recovery, and efficient adhesive free processing within the Lunatec Fusion system.
