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In this study, the foaming of nonwoven fabrics and bulk polymers was investigated. Four different polymers that are commonly used for textiles including polyethylene terephthalate, thermoplastic polyurethane, thermoplastic polyether ester elastomer and polypropylene were foamed by batch foaming. Among the polymers, thermoplastic polyurethane seems to be the most promising material since it possesses the highest cell density and smallest cell size. In addition, nanoclay was added to thermoplastic polyurethane to promote cell nucleation and to increase the cell density. The results showed that well dispersed nanoclay in thermoplastic polyurethane served as an excellent nucleation agent and the cell structure was improved. The cell size of thermoplastic polyurethane nanocomposite foam decreased to 1 µm while the cell density increased to 3 × 1011 cells/cm3.

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