What Are Waterborne PU Coatings?
Waterborne polyurethane (PU) coatings use water, rather than a chemical solvent, as the carrier for the resin, delivering the same durability and flexibility as solvent-based PU with a fraction of the environmental impact.
Traditional solvent-based coatings rely on carriers like DMF, NMP, and DMAC to deliver polyurethane onto fabric. These solvents are classified as carcinogenic, mutagenic, and reprotoxic (CMR) substances, and they release harmful VOCs during drying, creating real risk for factory workers and air quality across the supply chain.
Waterborne PU replaces those carriers with water. As a coated fabric dries, the water evaporates and the polyurethane particles fuse into a continuous protective film, the layer that gives the fabric its waterproofing, abrasion resistance, tear strength, UV protection, and hand feel.
Waterborne vs. Solvent-Based PU
Performance Comparison
PolyCore’s waterborne PU coating was lab-tested against a conventional solvent-based PU coating on the same 600D recycled polyester base using industry-standard test methods. The results below highlight where our waterborne technology matches or exceeds conventional solvent-based performance.
| Test Method | Solvent Based PU | PolyCore Eco-Coating |
|---|---|---|
| Abrasion (Cycles) ASTM D3389 H-18 1KG SP:65 | 2,642 | 10,000+ |
| Hydrostatic Resistance(mm-H2O)AATCC 127 | 700 | 3,500 |
| Puncture Resistance (Ibf) | 21.46 | 28.65 |
| Tear Strength (lbf) ASTMD2261 | Warp 20.1 / Fill 27.2 | Warp 21.3 / Fill 29.6 |
| Breaking Test (lbf) ASTMD5034 | Warp 308/ Fill 309.3 | Warp 333.3/ Fill 480 |
Sustainability Comparison
PolyCore’s waterborne PU coatings reduce VOC emissions by 98% compared to conventional solvent-based coatings and contain no intentionally added PFAS. Formulated to support compliance with EU REACH requirements, our coatings are also aligned with the ZDHC MRSL.
Benefits of Waterborne PU Coatings
- Lower environmental impact. 98% less VOC emissions than solvent-based alternatives, and equipment can be cleaned with water instead of harsh solvents.
- Safer to produce and handle. Lower toxicity and flammability mean a healthier manufacturing process.
- Strong performance. Comparable adhesion, flexibility, and abrasion resistance to solvent-based PU, holding up to the demands of outdoor and technical use.
- Aligned with where the industry is heading. Tighter environmental regulations in many regions are pushing manufacturers toward lower-VOC solutions, and waterborne PU is a big part of that shift.
- Regulatory alignment. Formulated to support compliance with EU REACH and the ZDHC Manufacturing Restricted Substances List (MRSL), with no intentionally added PFAS.
Why PolyCore Is Different
Most waterborne PU coatings form a protective layer on the surface of the fabric. Over time, that surface layer can wear down through abrasion, repeated flexing, or washing. While waterborne chemistry has advanced significantly, how the coating is applied remains just as important as the coating itself.
We have spent a decade understanding the nuances of waterborne coatings, and we have different techniques to maximize performance categories. These include proprietary application processes, carbon nanotube reinforcement, and hyper-specific curing instructions for each fabric/ coating combinations. Our team says that waterborne coating application is not only a science, but an art form.
Lab tests have shown PolyCore coatings can increase abrasion resistance by up to 500%, achieve hydrostatic resistance exceeding 10,000 mm, and deliver up to four times the tear strength of TPU coatings. Our clean chemistry achieves 98% lower VOC emissions than standard solvent-based coatings and no intentionally added PFAS. PolyCore coatings are formulated to support compliance with EU REACH requirements and follow the ZDHC MRSL.
Explore our Waterborne PU technologies
WATERBORNE PU · BACKSIDE COATING
Eco-Coating
Our waterborne PU coating penetrates deep into fabric fibers, increasing abrasion resistance by 500%.
Learn more
WATERBORNE PU · FACE COATING
Eco-Shield
Eco-Shield provides 10,000 mm hydrostatic resistance and 4x the tear strength of TPU without the environmental and social impact.
Learn more