Jumpinxflash: more than puncture protection

The technology is based on a fibre-reinforced composite material. During the research project, various fibres and matrix systems were tested and optimised in terms of functionality, technical properties and recyclability. The materials used include glass and carbon fibres embedded in a thermoplastic matrix. The result is an insert designed to combine puncture protection with additional functional properties. The soles have been tested in accordance with DIN EN ISO 22568-4:2022-01. Two versions are available: Jumpinxflash 300, with a stated puncture resistance of 1,200 newtons, and Jumpinxflash 400, rated at 1,400 newtons. According to the company’s technical data sheet, the two ver-sions weigh approximately 104 g and 125 g respectively, depending on the sole outline, and measure 3 mm and 3.5 mm in thickness. The 300 version has been tested over more than one million flex cycles, while the 400 version has undergone more than 1.5 million cycles.

For Rudolf Scherf, the appeal of the development lies precisely in the fact that it offers more than simply another alternative to steel and textiles. “Its performance characteristics are distinctive and new,” he says. Beyond puncture protection itself, he particularly highlights the material’s energy return and fatigue resistance. The composite sole can absorb energy during footstrike and release it again – a principle familiar from performance and running footwear. Additional benefits include torsional support and a stabilising effect.

These properties could be particularly relevant in applications where safety footwear is worn for many hours at a time. Scherf therefore sees potential not only in conventional occupational safety footwear, but also in footwear for firefighters, police officers, military personnel and other emergency and operational services.
Biomechanical studies also examined how the sole performs when the wearer is standing on a ladder. According to the developers, the construction provides a more favourable distribution of pressure beneath the foot. This is intended to reduce fatigue and improve wearing comfort during prolonged periods of standing or walking.

At the same time, the material is metal-free, electrically non-conductive and undetectable by metal detectors – properties that may be relevant in certain industrial, logistics and security environments. The construction is also designed to support and limit excessive bending of the foot, for example when standing on ladder rungs for extended periods or working in a kneeling position. Jumpinxflash does not regard the sole as a rigid, standardised component. According to Scherf, its shape and geometry can be adapted to the requirements of individual footwear manufacturers. Integration into different manufacturing processes is also envisaged. For example, the insert can be vulcanised into rubber or encapsulated in polyurethane (PU).

Perhaps the most interesting technological aspect, however, concerns the end of the product’s service life. From the outset, the research project addressed the question of whether a safety-critical component could not only be recycled, but potentially reused. Until now, puncture-resistant elements have generally been permanently integrated into footwear. Jumpinxflash takes a different approach. Although the coated composite sole is also incorporated into the shoe construction, it is designed to be removable at the end of the shoe’s service life. Once removed, the insert can undergo non-destructive testing. If it remains structurally intact and fully functional, it could potentially be used again in a new shoe. According to the technical data sheet, this involves non-destructive analysis using low-frequency measurements to identify possible structural damage, air inclusions or delamination. However, while the sole itself has been developed and tested, the infrastructure required for a complete take-back, inspection and reuse process is still being established. Scherf therefore describes circularity as a technically feasible option rather than a fully developed market-ready solution. Nevertheless, the material and testing procedure provide the technological basis for such an approach.

Jumpinxflash is currently preparing to scale up to series production. Manufacturing is presently taking place in Zülpich, Germany, while Scherf and Viethen are holding discussions with various footwear manufacturers. The intention is to keep future production in Germany or elsewhere in Europe wherever possible. According to Scherf, the raw materials are also currently sourced from Germany. The development addresses several key issues facing the safety footwear market: reducing weight while improving flexibility, maintaining high levels of protection, enhancing comfort during pro-longed use and exploring ways to extend the service life of components or return them to circular material flows. Above all, Jumpinxflash is interesting because its developers no longer regard puncture protection as an isolated safety function. Instead, a component that is already an essential part of safety footwear takes on additional functions – from energy return and torsional support to improved pressure distribution. And, at least from a technical perspective, it offers the possibility of remaining useful beyond the service life of its first pair of shoes.