Choosing the Right Thermoplastic Elastomer (TPE) for Injection Molding: A Practical Guide

We sometimes get questions about how thermoplastic elastomers (TPEs) differ from thermoset elastomers and which of the various TPEs would work best for a given part. One of the most fundamental differences between a part made with thermoplastics and one made with thermosets has to do with the chemistry that happens when the part is formed.

The Name is Bond…Chemical Bond

Thermoplastic elastomers (TPEs) differ from thermoset elastomers in the way their molecules attach to each other. Another difference is that TPEs can be processed on conventional injection molding machines. The resin is heated beyond its melting point, molded into shape, then cooled by the mold to solidify into its final form. 

Meanwhile, thermoset elastomers such as liquid silicone rubber (LSR) are molded into shape at lower temperatures, then high heat from the mold chemically crosslinks the polymer. This strengthens bonds between molecules.

One big difference between the two is that because they don’t undergo crosslinking during molding, TPE parts can return to a molten state, permitting recycling.

TPEs also provide the advantage of being able to be processed on the same equipment as standard thermoplastic resin, allowing for more optimized processes such as overmolding or multi-shot molding.

Triax Technologies used TPE overmolding to chemically bond to the substrate material, creating a waterproof seal for its IoT-enabled wearable device.

Types of Thermoplastic Elastomers

You can break TPEs into six primary categories that differ based on their chemical composition and structure:

• TPV: Thermoplastic vulcanizates
• TPU: Thermoplastic urethanes
• TPO: Thermoplastic olefins
• SBC: Styrenic block copolymers
• COPE: Copolyester elastomer
• PEBA: Polyether block amide

There can be substantial differences between each type of TPE and even the formulation of each subtype, so it’s important to pick the right material when considering part longevity and cost.

 

TPE Type	Trade Names	Chemical Resistance	Dimensional Stability	Density	High Tensile Strength?	Shore Hardness Range	Continuous Use Temp. Limit
TPV	Geolast Santoprene Sarlink	good	good	high	moderate	40A to 50D	135℃
TPU	Texin Elastollan Desmopan	excellent (for polyester-based formulations)	good (with additives)	high	yes	65A to 80D	120℃
TPO	Polytrope Hostacom Thermorun	good	good	low	yes	75A to 80D	120℃
SBC	K-Resin Kraton Asaflex	limited	good	low	low-to-moderate	15A to 50D	110℃
COPE	Hytrel Pibiflex Herafle	good	good	high	yes	90A to 80D	140℃
PEBA	Vestamid Pebax	good	good	low	yes	80A to 75D	170℃

TPV – Thermoplastic Vulcanizates

This is a hard thermoplastic material with regions of softer cross-linked rubber dispersed throughout its polymer matrix. In general, it offers a “soft” feel, matte finish, and high compression set. Be aware that it is not available in clear.
Applications: Seals, boots and grommets, bumpers, under-hood applications

TPU – Thermoplastic Urethanes

This is a block copolymer with alternating hard and soft regions on its molecular backbone, containing urethane linkages. TPU is noted for its mid-to-high hardness, good clarity, moderate compression set, and good wear, abrasion, and tear resistance. It’s suitable for outdoor applications and must be dried prior to molding. It’s also rather expensive. TPU is also distinguished as the only TPE available for 3D printing.
Applications: Protective cases, sporting equipment, medical equipment, footwear, in-line skate wheels

TPO – Thermoplastic Olefins

This is a “hard” polyolefin (typically polypropylene) blended with “soft” non-crosslinked rubber regions. Its high hardness yields a tough product with high impact strength. Some grades are weather-resistant. It has a low compression set and, unlike TPU, is comparatively inexpensive.
Applications: Automotive interior: dash, bumpers, roofing

SBC – Styrenic Block Copolymers

These plastics are made up of hard styrene regions and “soft” elastomeric regions arranged in alternating blocks, typically mixed with a more rigid polymer such as polypropylene. There are many different SBCs, so properties are often dependent on specific formulation. SBC is the softest and most flexible of all TPEs. It has a glossy surface, high elongation, good transparency, and good abrasion resistance.
Applications: Soft touch handles, buttons, knobs, grips; gel inserts

COPE – Copolyester Elastomer

COPE is a copolymer consisting of hard crystalline polyester regions and soft amorphous segments. It’s noted for its high temperature resistance, tear strength, and impact strength. It also has good creep resistance and low moisture absorption.
Applications: Furniture, auto boots, bumpers, prosthetics

PEBA – Polyether Block Amide

This copolymer consists of hard polyamide blocks alternating with soft elastomeric blocks. PEBA is noted for its good flex fatigue, creep, and impact resistances. It also does well in high temperatures, has a low compression set.
Applications: Medical equipment, sports equipment, electronics