Wacoal and BASF Collaborate to Expand 'Melooop' Technology into Automotive Industry

Wacoal Co., Ltd. (headquartered in Kyoto, President and CEO: Keisuke Kawanishi, hereinafter 'Wacoal'), a subsidiary of Wacoal Holdings Corp., is entering the automotive industry through a collaboration with BASF Japan Ltd. (headquartered in Chuo-ku, Tokyo, President: Hasbi Zaidam, hereinafter 'BASF'), leveraging its proprietary technology 'Melooop' for new applications.

A concept model designed for armrest applications will be showcased at BASF's booth during the 'Human and Automotive Technology Exhibition 2026 NAGOYA,' taking place from June 17 to 19, 2026. Wacoal established its R&D hub, the 'Melooop Lab,' in May 2026 to accelerate the development of new applications for this technology. This initiative is part of that broader strategy.

Expansion of 'Melooop' into the Automotive Sector through Collaboration with BASF

To expand the applications of its proprietary 'Melooop' technology, Wacoal has previously collaborated with BASF on joint development for bra cup applications using BASF’s thermoplastic polyurethane (TPU) material, 'Elastollan®.' Building on this successful partnership, Wacoal is now launching into the automotive field by applying 'Melooop' to new use cases.

'Melooop' is Wacoal’s unique technology that directly forms three-dimensional objects from fibers in a single step using the melt-blown method, enabling nonwoven structures without adhesives or multi-layer constructions. By simultaneously blowing fibers and forming 3D shapes, components can be molded as a single unit, significantly reducing manufacturing steps compared to conventional multi-process production. Additionally, by adjusting thickness and material properties during the design phase, it enables both lightweighting and functional performance tailored to specific applications. The technology also contributes to reduced environmental impact through efficient material usage and supports the durability required for automotive components.

These characteristics align well with the performance requirements and design needs of automotive parts, making it a promising area for 'Melooop' application. In this project, BASF’s Elastollan® TPU is selected as the ideal material compatible with the 'Melooop' molding process. Elastollan® TPU supports the 'Melooop' process with its combination of thermoplastic processability and elastomeric performance, enabling the creation of 3D fiber structures that balance flexibility and functionality. It also contributes to monomaterial design, simplifying product design and manufacturing processes.

The newly developed armrest concept model integrates BASF’s materials with the core 'Melooop' molding technology, exploring its potential application in automotive components from perspectives such as lightweighting, design flexibility, and recyclability. This exhibition serves as a representative example of application development centered on 'Melooop'.

Comments from Both Companies

Takeshi Hisamura, Executive Officer, Head of New Business Development Division, New Business Development Office, and Melooop Business Preparation Office, Wacoal Co., Ltd.

"Wacoal is committed to developing products that enhance comfort in everyday movement by integrating high-quality materials, creativity, and technological innovation. We are excited that through our collaboration with BASF, our 'Melooop' technology can now expand beyond apparel into automotive interior applications."

Rohit Roop Gosh, Vice President, TPU Business Management, Asia Pacific, Performance Materials Division, BASF Japan Ltd.

"Wacoal’s initiative to apply its proprietary technology to new application areas strongly aligns with BASF’s focus on advanced co-creation. We are pleased to leverage our expertise in material innovation and automotive applications to support customers like Wacoal in developing new concepts and expanding into new industries."

Future Outlook

Wacoal will continue to drive application development through co-creation with internal and external partners, using the 'Melooop Lab' as a hub. This automotive sector initiative is one example, and the company plans to explore applications in various other fields where nonwoven materials are used. As a material technology that combines low waste and recyclability with functionality, Wacoal aims to promote the social implementation of 'Melooop' to create new value and expand its business domains.

【Reference Information】

＜Human and Automotive Technology Exhibition 2026 NAGOYA＞

Event Name: 'Human and Automotive Technology Exhibition 2026 NAGOYA'

Dates: June 17 (Wed) – 19 (Fri), 2026

URL: https://aee.expo-info.jsae.or.jp/ja/nagoya/

＜Overview of 'Melooop'＞

'Melooop' is a new technology developed by Wacoal’s Human Science Research & Development Center, utilizing the melt-blown method—one of the nonwoven fabric manufacturing techniques—to create three-dimensional objects. In the melt-blown process, resin material is heated and extruded through a spinneret, then stretched into ultrafine fibers by high-speed hot air, while fibers are thermally bonded together to form a nonwoven fabric without using adhesives.

＜Key Features of 'Melooop'＞

① Monomaterial (single-material) construction using materials such as polyurethane or polylactic acid, enabling easier recycling

② 3D objects are formed by fiber deposition, minimizing material waste

③ Coloration is possible by adding dyes or pigments to the raw material, eliminating the need for dyeing processes

④ Molding onto 3D-printed molds eliminates the need for metal molds, making it suitable for small-lot production

＜About Wacoal Human Science Research & Development Center＞

Established in 1964, the Wacoal Human Science Research & Development Center is Wacoal’s research institute dedicated to scientifically exploring the human body from the perspectives of 'beauty,' 'comfort,' and 'health.' The data accumulated over nearly 60 years serves as the foundation of the company’s business, supporting not only new product development but also quality improvement and business expansion. In recent years, the center has advanced research into new materials and technologies while proposing product and service concepts based on consumer insights and the relationship between body and mind.

＜About BASF＞

BASF (Badische Anilin- und Soda-Fabrik) is a global chemical company headquartered in Ludwigshafen, Germany. Committed to creating chemistry for a sustainable future, BASF pursues economic success alongside environmental protection and social responsibility. With the ambitious goal of becoming the preferred partner for customers’ green transformation, BASF contributes to nearly every industry worldwide.

＜Overview of Elastollan® TPU＞

Elastollan® is