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In this work, post-consumer footwear waste is repurposed into thermal\/acoustic insulation materials for building construction, producing four needle-punched nonwovens (two of them compressed) composed of a post-consumer leather (30%) and footwear waste mixture (40%) with recycled polyester fibers. Nonwovens exhibited higher strain values (95.9 and 77.1% for leather residue and footwear mixture residue, respectively) but lower tensile strength (1694 and 104.9 kPa) and Young\u2019s modulus (1767.8 and 136.10 kPa). The compressed nonwovens demonstrated higher tensile strength (7360 and 3559 kPa) and Young\u2019s modulus values (12992 and 4020.4 kPa) and reduced strain (56.6 and 96.9%). The thermal conductivity results revealed that the nonwovens exhibited lower values (0.040 and 0.046 W\/(m\u00b7K)), indicating better insulation performance when compared with their compressed counterparts (0.060 and 0.058 W\/(m\u00b7K)). The nonwovens demonstrated high sound absorption at higher frequencies, reaching peak absorption coefficients of 0.917 and 0.995, ideal for acoustic insulation. The compressed nonwovens exhibited improved absorption at lower and mid-frequencies, with maximum values of 0.510 and 0.519. Given the current lack of applications for recycled materials derived from post-consumer footwear, the findings offer a novel approach to address their recycling.<\/jats:p>","DOI":"10.3390\/ma18204765","type":"journal-article","created":{"date-parts":[[2025,10,17]],"date-time":"2025-10-17T13:07:22Z","timestamp":1760706442000},"page":"4765","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":1,"title":["An Innovative Solution for Post-Consumer Footwear Waste: Nonwoven Fibrous Structures with Thermal and Acoustic Insulation Properties"],"prefix":"10.3390","volume":"18","author":[{"given":"Diana","family":"Alves","sequence":"first","affiliation":[{"name":"Textile Science and Technology Centre (2C2T), Department of Textile Engineering, University of Minho, Campus de Azur\u00e9m, 4800-058 Guimar\u00e3es, Portugal"}]},{"given":"Renato","family":"Guimar\u00e3es","sequence":"additional","affiliation":[{"name":"Textile Science and Technology Centre (2C2T), Department of Textile Engineering, University of Minho, Campus de Azur\u00e9m, 4800-058 Guimar\u00e3es, Portugal"}]},{"given":"Sofia","family":"Costa","sequence":"additional","affiliation":[{"name":"Textile Science and Technology Centre (2C2T), Department of Textile Engineering, University of Minho, Campus de Azur\u00e9m, 4800-058 Guimar\u00e3es, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-1848-726X","authenticated-orcid":false,"given":"Nuno","family":"Fernandes","sequence":"additional","affiliation":[{"name":"Center for Microelectromechanical Systems (CMEMS), Department of Mechanical Engineering, University of Minho, Campus de Azur\u00e9m, 4800-058 Guimar\u00e3es, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-9447-8739","authenticated-orcid":false,"given":"\u00d3scar","family":"Carvalho","sequence":"additional","affiliation":[{"name":"Center for Microelectromechanical Systems (CMEMS), Department of Mechanical Engineering, University of Minho, Campus de Azur\u00e9m, 4800-058 Guimar\u00e3es, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3303-6563","authenticated-orcid":false,"given":"Raul","family":"Fangueiro","sequence":"additional","affiliation":[{"name":"Textile Science and Technology Centre (2C2T), Department of Textile Engineering, University of Minho, Campus de Azur\u00e9m, 4800-058 Guimar\u00e3es, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-7862-4687","authenticated-orcid":false,"given":"Diana","family":"Ferreira","sequence":"additional","affiliation":[{"name":"Textile Science and Technology Centre (2C2T), Department of Textile Engineering, University of Minho, Campus de Azur\u00e9m, 4800-058 Guimar\u00e3es, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2025,10,17]]},"reference":[{"key":"ref_1","first-page":"92","article-title":"Characterization and Pyrolysis of Post-Consumer Leather Shoe Waste for the Recovery of Valuable Chemicals","volume":"14","author":"Nkomo","year":"2021","journal-title":"Detritus"},{"key":"ref_2","unstructured":"Portuguese shoes (2024). 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