From Leather to High-Tech

Back in the days – meaning up until the 1980s – footballs had real character: multi-layered, hand-stitched leather, often with a visible lace-up opening for reinflation. In the rain, the material would soak up water, making the ball heavier, harder – and more unpredictable. The Guardian reported 25 years ago on cases where former professionals, including a Celtic player, attributed later brain damage to these balls. Heading the ball back then required not only skill but neck muscles like a weightlifter’s. And anyone who had ever kicked a frozen leather ball in winter knew that even shin guards couldn’t absorb the impact entirely. The flight path was often capricious – sometimes the ball would float into the corner by chance, sometimes it would simply drop.

The introduction of coated leather in the 1980s, and later synthetic materials, eliminated many of these quirks. But it also brought new challenges: smooth surfaces could cause the ball to flutter unpredictably at certain speeds. Today, the goal is to combine precision, control, and durability so that the ball behaves identically under all conditions – whether in blazing sunshine, relentless English rain, or on frozen turf.

Engineered Turbulence

The ball’s journey begins not on the pitch but in the lab. Here, there are no goals – only millimetres and grams. Twelve identical panels ensure perfect weight distribution and stable flight paths. High-frequency welding of these panels guarantees shape retention even after thousands of strikes. The deep, large seams aren’t for looks – they’re precisely calculated structures that disrupt airflow at specific points. They create minimal vortices that reduce drag and keep the ball on course – especially during shots with spin. This principle has been scientifically studied, including at Sheffield Hallam University, showing just how closely aerodynamics and ball feel are linked today.

The surface is made from 3D-textured polyurethane. The fine structure provides grip for ball control and prevents slipping in wet conditions. At the same time, it enhances flight stability and protects against abrasion. A special valve system – the PAL valve (PUMA Air Lock) – keeps the air pressure constant, even over multiple training sessions and matches. The Orbita Ultimate PL’s high-contrast neon lines aren’t just eye-catching – they help players with ball orientation and allow referee cameras and VAR systems to precisely track spin and trajectory.

Clearly Defined Standards

Before the Orbita Ultimate PL can touch the pitch, it must pass the FIFA Quality Pro certification – the most demanding test cycle in professional football. The exact test criteria are set out in a 21-page FIFA handbook. It’s not just about basic values like circumference (68,5–69,5 cm), weight (420–445 g) and air pressure (0.6–1.1 bar). Standardised procedures check whether the ball retains its shape after 2,000 simulated shots against a steel plate, whether it bounces evenly when dropped from two metres, whether it absorbs no more than ten percent of its weight in water, and how much air it loses over 72 hours. Every one of these tests must be passed before the ball can be used in a professional match.

The standards were tightened after earlier controversies about unpredictable flight paths, excessive water absorption, or erratic bounces. In the past, international tournaments and league matches saw newly introduced balls draw heavy criticism – especially from goalkeepers, who voiced their concerns openly. Today, every model is tested until such surprises are eliminated.

When the players of Liverpool and Bournemouth put the new ball into motion for the first time, they probably won’t be thinking about vortex shedding, seam depth, or surface structure. But they will feel that the ball does exactly what it’s supposed to – with every pass, every cross, every shot.