Expafol’s TPU material traveled to one of the biggest sports venues on the planet. The 2026 World Cup brought the passion for soccer to three countries at once—Mexico, the United States, and Canada—and turned the tournament into a global celebration. In Mexico, our technical materials were part of that party, and they did it in a way that was hard to miss.
For this project, the TPU material was chosen to build the interior structure of a large-scale replica of the World Cup trophy: a spectacular piece, designed to be part of the experience that surrounded the tournament and to thrill the fans who came to see it.
A large-scale trophy, held from within
Reproducing football’s most desired trophy in a giant format is not just a matter of design: it is a challenge of materials engineering. An inflatable structure of these dimensions has to meet several requirements at the same time:
- Maintain its shape precisely, so that the replica looks imposing and recognizable.
- Resist continuous use and manipulation in a public setting.
- Be light enough to be easily assembled and disassembled.
Meeting all three at the same time is right where many materials fail. And it’s also where TPU makes a difference.
Why TPU Material Was the Right Choice
TPU (thermoplastic polyurethane) is one of the most versatile materials in Expafol’s technical catalogue, and its properties explain why it became the heart of this piece. These are the characteristics of the TPU material that made it ideal:
- Elasticity and flexibility: adapts to the complex shapes of a large replica without losing integrity.
- High mechanical and abrasion resistance: withstands tensions and intensive use without deteriorating.
- Excellent high-frequency weldability: allows watertight and reliable joints, which is essential in any inflatable structure.
- Lightness: a monumental piece is still transportable and easy to install.
That combination – strength, watertightness and lightness – is exactly what a large-format inflatable structure needs. That’s why the TPU material was able to flesh out a trophy that had to look spectacular while still running flawlessly throughout the event.
A collaboration with Air Designers
This project was made possible thanks to the collaboration with Air Designers, a Portuguese company specialized in the manufacture of large-format inflatable structures. Their expertise and craftsmanship gave life to this impressive creation, transforming the TPU material into a piece with an international stage presence.
The combination worked naturally: Expafol provided the technical material with the exact performance that the project demanded, and Air Designers provided the design, know-how and execution that make a TPU sheet a memorable work. It is a good example of how a good material and a good manufacturer enhance each other.
In a piece of these characteristics, the choice of material is not a secondary detail, but the starting point of the entire project. A TPU with the right properties facilitates each phase of the work – cutting, welding, inflation and final assembly – and reduces the margin of error in a structure that cannot afford failures in public view. This technical support, from the choice of material to the resolution of doubts during manufacturing, is part of the value that Expafol provides.
From the workshop to the World Cup stage
Seeing our solutions reach an international stage like the 2026 World Cup is a source of pride for the entire Expfol team. Not only because of the visibility, but because of what it represents: the confirmation that well-developed technical material can be behind moments that excite millions of fans around the world.
Projects like this summarize what we’ve been doing since 1991: developing flexible, high-performance materials – from TPU to PVC, glass to leatherette – that can solve challenges that others consider impossible, in more than 60 countries. Every demanding application is an opportunity to demonstrate what a well-thought-out material is capable of.
Do you have a project in mind with TPU material?
Whether you work with inflatable structures, industrial applications or any development that requires a reliable thermoplastic polyurethane, at Expafol we help you find – or develop – the right TPU material for your case. The same technical solvency that sustained a World Cup trophy is available for your next project.