Foams and Materials in Insoles This 2025: What You Need to Know

Footwear technology is evolving fast, and in 2025, we’re seeing smarter, more intentional design than ever before. From sustainable materials to performance-enhancing foams, the industry is shifting toward comfort, durability, and athletic optimization all without compromising on fit.

But even with all these new technologies, we’re not saying everything is going to be “the future of footwear foam”. 

At Orange Insoles, we stay at the forefront of that shift and we research which foam technologies are most effective for your feet! Here’s what’s new, what’s proven, and how our lineup is built to support real feet in the real world.

Why Foam Matters in Footwear

Foam is the backbone of comfort and support in both shoes and insoles. It’s what cushions your stride, protects your joints, and stabilizes your movements.

But not all foam is equal. The wrong material can break down fast, lose structure, or fail to absorb the impact of your daily routine. That’s why choosing the right foam and the right insole is critical.

The Top Foam & Insole Materials in 2025

1. O-Foam™ by Orange Insoles (NEW)

🟧 General Uses & Benefits of O-Foam (High-Rebound EVA)

Superior Energy Return: O-Foam doesn’t just absorb impact — it returns energy with every step. This makes walking or standing for long hours feel less fatiguing and more efficient.

Enhanced Shock Absorption: Compared to traditional EVA, O-Foam is formulated to absorb more shock without bottoming out, which helps protect joints and soft tissue.

Responsive Cushioning: It feels bouncy yet controlled — soft enough for comfort, but with the responsiveness to keep your stride smooth and supported.

Extended Lifespan: High-rebound EVA is more resilient over time, maintaining its structure and responsiveness even after heavy use.

Lightweight Feel: Despite the added performance, O-Foam remains extremely lightweight, making it ideal for both everyday wear and high-activity environments.

🟧 Why It Matters in Orange Insoles with O-Foam

When used in Orange Insoles, O-Foam brings a new level of comfort and performance, particularly for people who:1

Want more “spring” in their step

Are active, athletic, or looking for premium all-day support

You can expect:

More responsive cushioning for long-term comfort

More durable foam that resists flattening

An upgraded feel without sacrificing the alignment and stability Orange Insoles are known for

Depending on how it’s integrated (e.g., as a top cushioning layer above the rigid support structure), O-Foam could also enhance the feel of the deep heel cup and arch support, creating a premium step-in experience.

🧠 Quick Insight:

If traditional EVA is like a good mattress and compressed EVA is like firm memory foam, O-Foam is like a performance running shoe midsole — resilient, responsive, and ready for action.

2. Traditional EVA Foam

🟧 General Uses of Traditional EVA Foam in Insoles

Shock Absorption: EVA foam cushions the impact every time your foot hits the ground. This reduces the strain on your joints—especially in the heels, knees, hips, and lower back.

Energy Return: EVA both absorbs and deflects shock. That’s a good observation—a general rule of thumb is that traditional EVA foam can absorb around 40-60% of impact forces, while the rest is dispersed or returned as rebound energy, depending on the exact formulation.

Lightweight Comfort: It’s extremely lightweight, which means it can provide ample cushioning without adding bulk or weight to the insole.

Flexible Support: EVA compresses under pressure but rebounds to its original shape. This makes it adaptive to your foot's shape and movement, helping reduce fatigue over time.

Thermal Insulation: EVA has good insulating properties, which can help maintain a more comfortable temperature inside the shoe.

🔶 Why It Matters in Orange Insoles

In Orange Insoles, EVA foam is the third of four layers:

Polyurethane shell (for structure)

Rigid plastic shank (for alignment and arch support)

✅ EVA foam (for cushioning and shock absorption)

Antimicrobial top fabric (for odor and moisture control)

The EVA foam layer enhances comfort without compromising the structured support of the insole. It works in tandem with the deep heel cup and rigid arch to reduce pain from:

Plantar fasciitis

Heel spurs

Lower back strain

Fatigue from prolonged standing

3. Compressed EVA Foam

🟠 General Uses & Benefits of Compressed EVA Foam (as found in Orange Light Insoles)

High-Density Cushioning: Compressed EVA is denser and firmer than traditional EVA. It offers a more stable and supportive feel with less give, which is ideal for shoes that can’t accommodate full-size orthotic support.

Moderate Shock Absorption: It still cushions impact forces, but with less “squish” — which can actually be better for maintaining foot alignment and reducing foot fatigue in tight-fitting shoes.

Durability in Low Profile: By compressing the foam, it becomes more durable over time, resisting flattening or breakdown that typically happens with soft, low-profile foam inserts.

Minimal Bulk: Compressed EVA allows for a thinner insole without sacrificing essential support, making it perfect for flats, dress shoes, cleats, and other snug footwear.

🟠 Why It Matters in Orange Light Insoles

Orange Light Insoles are designed with:

✅ Compressed EVA Foam: Main material for support + cushioning.

✅ Anti-Microbial Fabric Top Layer: For odor and moisture control.

🛑 No rigid shell or deep heel cup: Unlike full/¾ insoles.

This design provides:

Light-to-moderate support for people who don’t have the room or need for the full structural build.

A great option for those transitioning into supportive insoles or who need relief in narrow-fitting shoes.

Relief from general fatigue, mild heel discomfort, and early-stage arch pain, while staying discreet.

🧠 Quick Insight:

While traditional EVA provides a balanced cushion, compressed EVA delivers more structure in tight spaces. It's a smart compromise for comfort and function where other insoles simply wouldn’t fit.

What's Trending in 2025

Alongside proprietary innovations like O-Foam™, here’s what the broader industry is seeing:

• Eco-friendly materials like sugarcane-based EVA and algae foam are on the rise for sustainability.
  
  

• Closed-cell foams and recycled polyurethanes are improving durability in performance shoes.
  
  

• Antimicrobial top layers and moisture-wicking covers are becoming standard to reduce odor and sweat buildup.
  
  

At Orange, we incorporate breathable top covers and durable bottom layers in all our insoles to improve lifespan and hygiene.

Spotlight: Orange Sport™ and the Rise of Performance Foam

Athletes know every detail matters, from training cycles to gear choice. That’s why Orange Sport™ is our most advanced insole to date.

It features:

• ✅ Slim Athletic Profile: Designed to fit running shoes, cleats, and tight athletic footwear
  
  

• ✅ High Rebound O-Foam™: Engineered for durability and power, with 40% energy return
  
  

• ✅ Medial Arch Support: Keeps feet aligned and reduces fatigue
  
  

• ✅ Metatarsal Pad: Evenly distributes pressure and prevents common overuse injuries
  
  

Unlike our Orange Full insole, which is made for everyday wear, Orange Sport™ is built specifically for intense, dynamic movement. And it does it all without cramming your foot or altering your shoe’s fit.

If you need performance that matches your pace, Orange Sport™ is the upgrade your feet will thank you for.

Choose Based on How You Move

Here’s a quick breakdown:

The Future of Foam Is Here

As footwear continues to evolve, so should the way we support our bodies. Foam isn’t just filler, it's functional. It affects how you move, how you recover, and how you feel at the end of the day.

With O-Foam™ and a range of materials designed for real-world use, Orange Insoles is proud to bring the future of foot support to you whether you're grinding out a shift, training hard, or just walking the dog.

Shop our full insole lineup now and experience support that’s built smarter.

🧠 Quick Insight:

Orange Insoles don’t rely solely on EVA like some cheaper inserts. EVA gives comfort, but it’s the combo of EVA + structure that makes them effective for serious support. Without that structure, too much EVA alone would just compress and wear out quickly.