Dryflex HiF: Ultra‑High‑Flow TPEs Empowering Sustainable, Lightweight Automotive Interiors

A new family of ultra‑high‑flow, scratch‑resistant thermoplastic elastomers (TPEs) has been launched by Hexpol TPE, a leading polymer compounding group headquartered in Sandusky, Ohio. The Dryflex HiF grades open doors to producing large‑scale automotive interior components—such as instrument panels, door trims, and skins—via injection molding while meeting the industry’s growing sustainability demands.

“Current solutions for automotive interiors, like PC/ABS‑based TPU or PU‑RIM processes, are expensive and not recyclable,” says Dr. Thomas Köppl, product manager at Hexpol TPE. “Our Dryflex HiF TPEs combine high performance, a soft‑touch feel, optimal processing, and full recyclability, giving OEMs a cost‑effective, greener alternative.”

Hexpol worked closely with Kraton Corp. to build the Dryflex HiF line on Kraton’s IMSS technology platform. The result is a material that delivers a soft, tactile feel, superior abrasion resistance, and excellent melt‑flow, while remaining fully recyclable.

Because the grade adheres well to polypropylene, it can be used in two‑component (2K) overmolding, replacing heavier PC/ABS rigid layers. This capability reduces both cost and vehicle weight, a win for OEMs seeking lighter, greener interiors.

Traditional TPEs have been limited to smaller trim pieces—mats, grips, and sealings—due to stricter requirements for abrasion, heat resistance, and processability in large parts. Dryflex HiF TPEs meet those demands, making them a viable injection‑molded alternative to PU coating, PVC slush molding, and TPO foil processes.

In a production trial, engineers molded a 1.1 mm thin skin for a complete instrument panel and back‑foamed it with PU. The high melt‑flow of Dryflex HiF enabled the creation of a large, thin part without visible weld lines, achieving a low‑gloss, matte finish that can mimic leather grains.

Extensive testing confirms that Dryflex HiF TPEs withstand 1,000 hours at 120 °C (248 °F), meeting stringent lightfastness and heat‑resistance criteria for instrument panels. Performance metrics—including Erichsen scratch resistance and Crock abrasion—also demonstrate its suitability for demanding automotive interior applications.