The History of PU Coatings
Modern backpacks and jackets rely heavily on polyurethane coatings for durability and waterproofing, but PU is a relatively recent development. For centuries, people relied on natural methods such as oils, waxes, and rubber to protect fabrics from rain and moisture. They worked, but were often heavy, stiff, and quick to break down. Today, we’re here to tell the story of the development of polyurethane coatings in the outdoor industry.
As travel, industry, and outdoor recreation evolved, expectations changed. Designers and engineers began searching for materials that were lighter, stronger, and capable of standing up to harsher conditions without sacrificing flexibility or comfort. The textile world needed a breakthrough.
That breakthrough arrived in 1937, when German chemist Dr. Otto Bayer discovered polyurethane while working at IG Farben. His research introduced an entirely new class of polymers created by reacting polyols with diisocyanates. The result was something scientists had been chasing for decades: a material with performance that could be finely tuned for different uses.
Otto Bayer demonstrates a foam test with polyurethane during a lecture. (Photo from 1952, Source: Bayer AG)
At first, polyurethane had nothing to do with textiles. It was developed as a versatile industrial material, used in coatings, foams, elastomers, and adhesives across a wide range of applications. When World War II disrupted global supplies of natural rubber, synthetic alternatives quickly became essential. Polyurethane emerged as a durable and flexible substitute, finding widespread use in industrial coatings and military applications. The urgency of wartime production accelerated its adoption, pushing PU from a laboratory discovery into large-scale commercial use.
This period laid the foundation for polyurethane’s eventual evolution into one of the most important materials in modern performance textiles.
From Industry to Everyday Life
After the war, polyurethane did not slow down. Instead, it began quietly weaving itself into everyday life. Scientists and manufacturers realized that by adjusting formulations, PU could be made soft or rigid, flexible or tough, smooth or textured. This adaptability opened the door to entirely new applications.
In the 1950s, one of the first major consumer uses of flexible polyurethane appeared in furniture upholstery and synthetic leather. PU offered the look and feel of leather without the cost or weight, and it proved to be remarkably durable. Around the same time, footwear brands began using PU for sneaker soles, drawn to its cushioning, abrasion resistance, and long lifespan. These early consumer applications helped establish polyurethane as a reliable performance material.
PU Enters the Outdoors
It was not until the 1970s that polyurethane truly found its place in textiles. This moment coincided with the rapid growth of outdoor recreation. Hiking, climbing, and backpacking were becoming mainstream, and with them came a demand for lighter gear that could survive harsh weather.
Traditional waterproofing methods were no longer sufficient. Rubberized fabrics were heavy and stiff. Waxed materials required constant maintenance. Outdoor brands needed something better. Polyurethane coatings provided the answer. Applied to the back of woven fabrics, PU creates a waterproof barrier while preserving flexibility and reducing weight. For the first time, designers could create packs and apparel that were durable, weatherproof, and comfortable to carry.
Kelty catalog 74-75 Winter
Brands like REI, Kelty, and Blacks played a key role in bringing PU-coated fabrics into the outdoor mainstream. Interestingly, polyurethane was rarely advertised. It was a quiet innovation, hidden on the inside of the fabric, yet it dramatically improved abrasion resistance, tear strength, and waterproof performance. PU became the unsung hero of durable outdoor gear.
The following photos are early examples of the adoption of PU coatings in outdoor products. These images were provided by the Utah State University Outdoor Recreation Archive
Kelty catalog 69-70
Blacks 70 Blacks 68
Rethinking PU for the Future
Today, the industry is at another turning point. Just as consumers and brands once demanded lighter and stronger materials, they are now demanding safer and more responsible ones. The question is no longer whether polyurethane belongs in high-performance textiles, but how it can evolve.
At PolyCore, we believe polyurethane is an essential component of high-performance materials. However, the use of toxic solvents as a dispersion is no longer necessary. By reengineering PU coatings to be water-based, we eliminate the need for harmful solvents while preserving the performance that made PU indispensable in the first place.
The history of polyurethane coatings is a story of innovation, adaptation, and quiet impact. From wartime necessity to outdoor essentials, PU has shaped the gear we rely on every day. The next chapter is about doing it better, for the people who make our products and for the environments we explore with them.
