In my daily work, TPE (thermoplastic elastomer) is one of the materials I come into contact with the most. It is as soft as rubber but can be processed like plastic. It is widely used in automobiles, medical treatment, electronics and daily necessities. In this article, I want to take you from scratch to fully understand the definition, types, advantages and disadvantages, processing methods, application fields, safety of TPE and how to choose the right TPE material.

Cosa Is TPE 

TPE, the full name of which is thermoplastic elastomer, is a polymer material that has both rubber elasticity and plastic processing properties. It exhibits the softness and elasticity of rubber at room temperature, and can melt and flow when heated to a certain temperature (usually 170°C~230°C), making it suitable for various molding methods such as injection molding, extrusion, and blow molding, and it will return to its original shape after cooling.

We usually call TPE “deformable rubber” because it can be repeatedly processed on the production line and can exhibit lasting softness and resilience when used.

Il Essential Principle Of TPE

The essential structure of TPE is a copolymer system composed of “hard segments” and “soft segments”. The hard segments (such as polystyrene, polyester, polyamide, etc.) provide thermoplasticity at high temperatures, enabling melt processing capabilities , while the soft segments (such as polybutadiene, polyether or polyester) give the material rubber-like elasticity and flexibility. It is this “physical cross-linking” microstructure that enables TPE to achieve excellent elastic recovery without relying on traditional chemical vulcanization.

Take my factory as an example. When we customized a batch of baby teether products for a European customer, we used SEBS substrate (styrene-ethylene-butylene-styrene copolymer). The material hardness was set at 60 Shore A. It has stable elasticity and a warm feel. It has passed the EN71 toy safety standard and REACH phthalate-free directive test. The customer spoke highly of the tensile strength (≥7 MPa) and compression recovery rate (>85%) of the finished product.

Confronto Wcon Traditional Rubber And Plastico

Compared with traditional materials, TPE has significant advantages in structural principles and application efficiency. Traditional rubber relies on chemical cross-linking to form a permanent network structure, which requires a long high-temperature vulcanization process. The molding cycle is usually 5-10 minutes , and the finished product is not recyclable . Although plastic can be quickly molded, it lacks elasticity and the hardness range is concentrated above 60 Shore D, which cannot meet the use requirements of flexible contact products. TPE has successfully broken this limit. It not only has an adjustable hardness range of 0A60D, but can also be recycled and reused. The scraps can be crushed and put back into the processing system to reduce material waste.

We once produced a mobile phone protective case for a 3C customer, and selected TPE-S material as the outer layer of the rubber coating, which has both anti-slip and shockproof functions. The compression deformation rate of this material is only 10% under 50°C, while conventional PVC exceeds 25% under the same conditions. This shows that TPE can effectively control structural fatigue after long-term use while maintaining elastic deformation. This balance between processing flexibility and performance is where I think TPE truly “changes the rules of the industry.”

Cosa Are Tlui Types Of TPE

Common types of TPE include five categories: TPE-S, TPV, TPU, TPC, and TPE-A. Although these types are all thermoplastic elastomers, their molecular structures, performance parameters, and applicable fields vary greatly. In actual projects, I often choose the appropriate TPE type based on the specific needs of customers, such as heat resistance, wear resistance, hardness, biocompatibility, etc.

TPE-S

TPE-S is the type I recommend most often to my clients, especially in the field of daily consumer goods and baby products. This type of material has a structure of styrene-elastic segment-styrene (such as SBS, SEBS), good elasticity, soft feel, and a wide range of adjustable hardness, from 5 Shore A to 90 Shore A. Its biggest advantage is easy processing, good thermal stability, can be injection molded or extruded at a heating temperature between 180°C and 220°C, and can bond well with PP and PE rubber.

The baby teether we produced for a European customer uses SEBS-based TPE, which is required to be soft and odorless, with a hardness of 60 Shore A, and fully meets EN71 and FDA certification standards. The raw material procurement cost is about 28 yuan/kg, the processing cycle is short, and the yield rate exceeds 97%.

TPV

TPV is the type of TPE I use most in automotive projects, especially for parts such as seals and jackets. It is made of dynamically vulcanized EPDM rubber particles dispersed in a polypropylene (PP) matrix. It has rubber-like resilience and can be processed by thermoplastics. TPV has better heat resistance than TPE-S, and can generally withstand continuous 120°C and short-term up to 140°C, and has excellent oil resistance and aging resistance.

We have developed automotive window seals for an American customer, using Shore A 70 TPV material. After 3,000 hours of cycling at -40°C to 130°C, the compression set is controlled at 18%, which is much better than traditional EPDM rubber. The price of TPV material is slightly higher, usually 32~38 yuan/kg, but its durability makes up for the initial cost.

TPU

TPU is a material that has both high strength and high elasticity. I especially like to choose TPU in situations that require high wear resistance or tear resistance, such as soles, wheel rubber coating, industrial tool handles, etc. TPU is divided into two types: polyester and polyether. The former has good oil resistance and wear resistance, while the latter has stronger hydrolysis resistance. The hardness range is usually 60A75D, the tensile strength is generally 2550 MPa, and the elongation can reach 600%.

We have made a heavy-duty portable tool encapsulation using polyester TPU (Shore hardness 95A). After 100,000 friction tests, the wear thickness was less than 0.2mm, which is much better than SEBS materials. TPU molding temperature is relatively high, requiring 220~250°C during injection molding, and the processing window is relatively narrow, but the strength performance is excellent.

TPC

TPC is a TPE with “engineering grade” performance, taking into account thermal stability and mechanical strength, and is suitable for more demanding industrial applications, such as automotive engine pipes, cable sheaths, pressure joints, etc. It is characterized by high melting point, good fatigue resistance and chemical resistance, and a continuous operating temperature of more than 150°C.

We have developed an extruded TPC for a German customer for the protection of industrial robot joint wiring harnesses. The material is made of PBT and PTMEG block copolymer, with a bending fatigue life of more than 5 million times. It can maintain stable physical properties even after long-term exposure to industrial oil mist and meet the UL 94 V-0 flame retardant requirements.

TPE-A

PEBA is a very unique material that combines low-temperature flexibility, chemical resistance and high resilience. It is one of the main materials I use in high-end medical and avionics. Its structure is a polyether-polyamide block copolymer, which can maintain good elasticity and impact resistance at -60°C, and the highest temperature resistance can reach 170°C. At the same time, it has low water absorption and good electrical insulation performance.

We provided PEBA material (hardness of approximately 72 Shore D) for a cardiac catheter component. After being immersed in saline at 37°C for 1000 hours, the dimensional change was controlled within ±0.3%, and various biocompatibility tests were fully in compliance with ISO 10993 standards.

These five types of TPEs have common thermoplastic elastic characteristics, and each has its own professional performance advantages. In my project practice, choosing the right TPE type is far more important than simply choosing a “cheap” or “moderately soft and hard” material. If you don’t know which TPE is suitable for your application scenario, start thinking about what your product needs to “bear”.

Cosa Are Tlui Processing Methods Of TPE?

We can use a variety of industrial processing techniques to shape TPE, including injection molding, extrusion, blow molding, and even CNC and 3D printing in certain cases. Different processes have their own advantages, and the specific choice depends on factors such as product design, production volume, and precision requirements.

Iniezione Minvecchiamento

This is one of the TPE molding methods I use most often. TPE can be heated, melted, and cooled to form like plastic, and a single injection molding cycle can be as low as 15 seconds . I once mass-produced a SEBS baby teether for a customer, shipping 100,000 pieces per month, with an injection mold life of over 300,000 molds, and product dimensions stable within ±0.1mm. It is suitable for large-volume, complex-shaped, and high-surface-requirement products.

Extrusion

The flexibility of TPE is particularly suitable for continuous profile production, such as cable sheaths, sealing strips, hoses, etc. I have used TPV materials to develop door sealing strips for automotive customers. The line speed is controlled at 8~15 meters/minute , the cross-sectional size tolerance is ±0.2mm, the surface finish is high, and it has a certain elastic recovery.

Blow Minvecchiamento And Blown Film

Some TPE types, such as TPU and TPE-E, have good melt stretching properties and can be used in the production of hollow products and films. For example, TPU sports water bottle soft bladders and food soft packaging. When making samples, I set the wall thickness to 0.5mm, and achieve uniform thickness control through secondary inflation to ensure that the tensile strength exceeds 25 MPa .

3D Printing

TPE is also suitable for 3D printing, especially TPU type TPE, with a printing temperature of 210~240°C . I have used TPU 85A hardness material to print flexible insoles and shock-absorbing structures, with a stretch rate of more than 500% , which is suitable for small-scale customization and structural testing. It should be noted that the printing speed should generally not exceed 30mm/s to ensure adhesion and accuracy.

CNC Mrammendo

Although TPE is not the first choice for CNC machining, I have also used CNC to cut TPE with Shore D ≥40 in the prototype verification or mold-unready stage. Sharp tools, low speed (4000~6000rpm), and air cooling are required for machining. I have used this method to make sealing insert samples for customers, with an error control within ±0.2mm. However, due to low efficiency and rough surface, it is more for temporary verification purposes.

Vantaggi And Disadvantages Of TPE

In my projects, TPE is frequently selected due to its “good elasticity and fast processing”. Its advantages are: wide hardness range (3A-60D), injection molding and extrusion, non-toxic and environmentally friendly, and recyclable , but its disadvantages are also obvious, such as poor heat resistance (generally <120°C), weak oil resistance, reduced rebound after long-term stretching, and the raw material cost is about 30% higher than PVC. These characteristics must be weighed when choosing.

Avantaggio

Forte Aadattabilità The most prominent feature of TPE is that it is “as soft as rubber”. Its hardness range is wide, covering from 3 Shore A to

 60 Shore D. Taking SEBS TPE as an example, at a hardness of 60 Shore A, its rebound rate can reach more than 70%, and its compression permanent deformation rate is less than 25%. It has good performance in the fields of children’s toys, sports equipment, knee pads, etc. I once customized a batch of TPE injection molded parts for a European medical customer, which required a stretch rate of more than 500%. In the end, the actual test data of the material we selected reached 620%, which fully met the performance requirements.

Flexible Processing

TPE supports a variety of thermoplastic processing methods, including injection molding, extrusion, blow molding, thermal bonding, etc. I often use TPE for two-color injection molding. The material melts stably in the temperature range of 180-230℃, and the injection molding time is as short as 12-15 seconds. Compared with traditional rubber, TPE does not require vulcanization, and the processing cycle is shortened by more than 40%, which greatly improves production efficiency and is especially suitable for large-scale rapid production.

Sicurezza And Environmental Protection

High-quality TPE materials basically do not contain plasticizers, heavy metals or toxic solvents, and can meet food contact regulations such as FDA CFR 177.2600, EU No.10/2011, etc. Many baby projects I handle, such as teethers, pacifiers, and chew toys, all use TPE-S (SEBS) series, which meets the EU EN71 Part 3 safety standard, and the volatile TVOC value is less than 0.2 mg/m², which is very suitable for skin-friendly applications.

Recyclable Processing

As a thermoplastic material, TPE can be melted and reprocessed, and its scraps and waste can be directly crushed and recycled, with a recycling efficiency of up to 95%. In an electronic casing production line I am involved in, recycling TPE scraps can save about 8% of raw material costs per month, which is both environmentally friendly and reduces operating costs.

Sin arrivo

Limitato Heat Resistenza Most general-purpose TPEs will experience physical property degradation under high temperature (>120°C), such as softening, sticky surface, and structural instability. Taking SEBS as an example, its long-term use temperature is recommended to be controlled at -40°C ~ 100°C, and the short-term temperature resistance should not exceed 120°C. In automotive engine compartment applications that require high temperature resistance, I would prefer to use TPV or silicone. In comparison, the upper limit of silicone heat resistance can reach 200~250°C, which is more advantageous.

Unstable Cemico Properties. Ordinary TPE will expand in volume or decrease in hardness when in contact with certain oils, aromatic hydrocarbons or ester solvents. Tests show that after contacting diesel for 72 hours at 25°C, the volume expansion rate of general SEBS is as high as 18%, while that of TPU is only 7% and that of TPV is about 9%. Therefore, in the environment of lubricating oil and gasoline, I usually choose TPU or TPV to enhance oil resistance.

Alto Cost

According to the data I have purchased so far, the market price of SEBS is about 2.5-3.0 USD/kg, while that of PVC is about 1.8-2.0 USD/kg. The price of TPU is even higher, usually above 3.5 USD/kg. Therefore, for highly price-sensitive items (such as disposables or cheap toys), the cost advantage of TPE is not obvious.

Facile To Deform Especially some low-density TPE, when stretched more than 200%, its stress recovery ability decreases significantly. For example, when I was testing a non-slip handle, I found that ordinary TPE-S loosened after stretching to 300%, and the permanent deformation rate reached 22%, which is much higher than the 15% Required by customers. For such high-stretch, long-term stress-bearing parts, I usually recommend using SEPS or modified TPU to enhance recovery ability.

In general, TPE is an excellent engineering material suitable for projects with high requirements for softness, safety and processing efficiency. But it also has limitations – especially when used in high temperature, high oil, and high stress scenarios, you need to choose it with caution. When selecting materials, I always follow the principle of “performance adaptation is more important than material universality”, and strive to find a balance that both meets functions and controls costs.

Come Is TPE Made?

TPE is usually made through a precise combination of different polymers (thermoplastic components and elastomeric components), plus appropriate amounts of additives, stabilizers, and processing lubricants, and is ultimately manufactured through reaction or blending processing equipment. The manufacturing methods of different types of TPE vary significantly, and it is these process details that determine whether it can be used in a variety of applications from baby products to the automotive industry.

Here are the common manufacturing methods I have sorted out for you:

Copolymerization Method (Used For TPU, TPE-E, Etc.) I have cooperated with TPU suppliers for material optimization many times. TPU is manufactured by reacting polyols (such as polyesters or polyethers) with diisocyanates to form polyurethane segments, which are then connected to form thermoplastic elastic structures through chain extenders. This type of reactive TPE is extremely sensitive to reaction temperature and ratio control. The initial reaction is generally completed at 70-90°C, and the polymerization reaction yield is above 95%. The hardness of the final TPU particles ranges from 60A to 75D, and has good tensile properties and wear resistance.

Dynamic Vulcanization Blending Method (Mainly Used For TPV) The preparation of TPV is a typical physical and chemical cross-process. In one of my client projects, we used polypropylene (PP) and ethylene propylene rubber (EPDM) to mix in proportion and added a vulcanizer for dynamic vulcanization at 170~200°C. In this process, the rubber cross-links in the plastic matrix to form a fine rubber particle dispersion, which has both elasticity and thermoplasticity. We pay special attention to controlling the rotation speed and time to ensure sufficient vulcanization and prevent abnormal particle size distribution from affecting the dimensional stability of the product.

Physical Blending And Additive Modification (Applicable To TPE-S, TPE-O) Many TPE-S (styrene-based TPE) are obtained by blending elastomers such as SEBS and SBS with thermoplastics such as PP and PE. During the blending stage, we will add plasticizers (such as white oil) and fillers (talcum powder or calcium carbonate) to adjust the hardness, surface feel and cost. For example, a typical daily handle material has a TPE formula with SEBS accounting for about 35%, PP base material accounting for about 40%, and the rest being oil and additives. The final hardness can be controlled at around 70 Shore A, with excellent elasticity and grip.

When developing a TPV seal for vehicle ventilation systems, I helped the factory adjust the mixing temperature range to between 180 and 200°C and set the speed to 80rpm to ensure that the EPDM was fully vulcanized and evenly dispersed. The thermal aging performance of the final tested product reached the standard of 120°C × 1000 hours without cracks, meeting the customer’s requirements for high temperature durability.

Application Fields Of TPE

TPE has been widely used in automotive parts, medical devices, electronic equipment, daily necessities and even 3D printing. Especially in the sub-categories such as TPV and TPU, its performance has been verified by a large number of actual cases, effectively meeting the personalized needs of different industries for materials.

Is TPE Safe?

In the many medical device and baby products projects I have led, “Is the material safe?” is almost the most frequently asked question by customers. My answer has always been very clear: TPE can be highly safe . It not only meets many international standards, but also has excellent biocompatibility, chemical stability and low toxicity. It is one of the most reliable materials in the medical and food contact fields.

we commonly use have passed the following certifications:

FDA GRAS : Most TPEs can be included in the FDA food contact material list and are suitable for baby pacifiers, drinking water devices, etc.

ISO 10993 Series : This is the international standard for the biocompatibility of medical device materials. The TPU and TPE-A materials I use have passed key tests including skin irritation (-10), cytotoxicity (-5), systemic toxicity (-11), etc.

USP Class VI : Many medical projects require materials to pass the United States Pharmacopoeia’s highest level standard for biomaterials, and more and more TPE materials have passed this standard.

In terms of temperature stability, the medical-grade TPE we use can withstand high-pressure steam sterilization (121°C, 15 minutes) without degradation , and the thermal deformation rate is less than 2.5% , which is the basic requirement for commonly used sterilization conditions in hospitals.

As for migration and residue, according to our third-party test data, the monomer migration residue of SEBS-type TPE is generally less than 0.01 ppm , which is far lower than the requirements of EU EN71 and REACH regulations for children’s product materials.

In an actual case, we developed a baby teether for a European customer. The material used was Shore A 60 transparent TPE . It not only passed the German LFGB test , but also received no allergy complaints in the 24-month after-sales feedback . This is a very trustworthy record in the field of baby products. For me, whether to choose TPE is not just a performance issue, but also a matter of user health and trust.

Domande frequenti

Cosa Are The Disadvantages Of TPE?

In my experience, TPE has limited heat resistance (mostly <120°C), is easy to swell in oil environments, has decreased long-term tensile rebound, the deformation rate of SEBS-type TPE can reach 22%, and the raw material cost is more than 30% higher than PVC.

Is TPE Or TPU Better?

I usually select materials based on performance: TPU is more wear-resistant and oil-resistant, with a tensile strength of up to 50 MPa, making it suitable for industrial parts ; TPE is softer and easier to process, with a price around 30% lower, making it suitable for daily necessities and rubber encapsulation projects.

What Is The Difference Between TPE And PP?

TPE is elastic, with a hardness range of 3A–60D, and is suitable for skin-friendly products , while PP is a rigid plastic with a hardness of more than 80D. When I use TPE to encapsulate PP, the two can achieve good adhesion.

What Is The Difference Between TPE And TPV?

TPV is a type of TPE with stronger heat resistance (continuous 120°C) and aging resistance. I often use TPV in automotive sealing projects, and its service life can be more than twice that of traditional rubber.

What Is The Difference Between TPE And LDPE?

TPE is more elastic than LDPE (stretching rate>500%) and supports injection molding and encapsulation . LDPE is mainly used for film, which is soft but not resilient. When I use TPE instead of LDPE, it feels more comfortable and has better fatigue resistance.

What Is The Difference Between Polyolefin And TPE?

Polyolefin refers to rigid plastics such as PE and PP, while TPE combines rubber elasticity with plastic processability. I often use TPE as a flexible coating layer for Polyolefin products to improve anti-slip and tactile properties.

Is TPV Plastic?

Yes, TPV is a thermoplastic elastomer that can be processed by thermoplastics. I have used TPV to make high temperature resistant seals, which can maintain a compression recovery rate of >80% when working at 120°C for a long time.

Is Polystyrene A TPE?

No. Polystyrene (PS) is a rigid plastic and is not elastic , but TPE-S does contain styrene block copolymers (such as SEBS), which I have used to develop elastic toy shells.

Can You Melt TPE?

Yes. TPE is a thermoplastic material that can be melted and injected or extruded when heated to 170-230°C. When my factory molds teething products, the melt temperature is set at 200°C and the cycle time is only 15 seconds.

Is TPE a Silicone?

TPE is not silicone. It does not contain silicone chains and has a slightly lower heat resistance (≤120°C). I usually use silicone in situations where high-temperature steam sterilization is required, such as 121°C pressure sterilization, which can still maintain structural stability.

Conclusione

TPE is a family of materials that are soft, processable, and environmentally friendly. By properly selecting the model and process, it can almost meet the needs of various industries for “softness, durability, and safety.” I hope this article can help you truly understand TPE and use it well in product design!