Thermoplastic polyurethane changes the math on inner tubes. Schwalbe developed Aerothan in partnership with BASF over five years of testing, creating a material that sheds roughly 40% of the weight compared to standard butyl tubes while simultaneously improving puncture resistance. The tube feels different in your hands before it even goes on the rim: semi-transparent, slick to the touch, and noticeably lighter than what you're used to pulling out of a box. That weight difference translates directly to rotational mass savings at the wheel, where every gram matters more than it does elsewhere on the bike.

Puncture testing tells a compelling story. Schwalbe's plunger test, which simulates glass shards and small debris, shows Aerothan requiring 47 newtons of force to penetrate, more than double what standard butyl withstands. The material also resists pinch flats better than traditional tubes in guillotine testing, partly because of inherent toughness and partly because of exceptional shape stability at lower pressures. When an Aerothan tube does puncture, air escapes gradually rather than catastrophically, often leaving enough time to reach a safe stopping point.

The TPU construction extends to the valve stem itself, eliminating the metal-to-rubber junction where many tube failures originate. Heat resistance certification means the tube handles extended rim brake descents without the degradation that can affect butyl at high temperatures. Installation goes smoothly since the slick surface slides into position without bunching or catching under the tire bead. The tube maintains dimensional stability even when partially inflated, making it easier to seat the tire without trapping the tube.... Read More