Is TPE or TPU better?

In the field of materials science, TPE (thermoplastic elastomer) and TPU (thermoplastic polyurethane) are extremely important polymer materials, each of which has its own unique properties and is widely used in different fields. As for which is better, TPE or TPU, this cannot be easily determined, after all, “good” and “bad” depend on the specific application scenario and needs. Next, this article will compare and analyze TPE and TPU from multiple perspectives to help readers gain an in-depth understanding of the characteristics and application scenarios of these two materials.

What is TPE (Thermoplastic Elastomer)?

Thermoplastic elastomer(TPE) belong to a class of polymer materials that have the properties of both rubber and thermoplastics. Its key feature is that it can be molded using thermoplastic processing methods such as injection molding, extrusion, blow molding, etc., without the need for vulcanization. TPEs have the elasticity of rubber and are as easy to process as plastics. At room temperature, TPE exhibits high elasticity of rubber; At high temperatures, it melts and flows like plastic, and when cooled, it regains elasticity, which is why TPEs are called “third-generation rubber”.

What is TPU (Thermoplastic Polyurethane)?

Thermoplastic polyurethane (TPU) is a polymer material composed of diisocyanate, polyols and chain extenders. It combines the properties of polyurethane elastomers, such as high strength and good toughness, as well as the ease of processing of thermoplastics, making it known as the “fifth largest plastic”. TPU is resilient over a wide temperature range of -40°C to 120°C and is resistant to oil, water and mildew.

 How Do Their Printability Parameters Differ?

TPE and TPU differ in a number of printability parameters, including print temperature, extruder requirements, print speed, and layer height settings. The following is a detailed comparison of the printability parameters of these two materials.

Printability parameters of TPE

• Extrusion temperature: The extrusion temperature of TPE is generally in the range of 170 – 220°C. Due to the high elasticity of TPE, it is essential to use an all-metal hot end when printing to prevent clogging.
• Pullback settings: When printing TPE, the pullback function must be turned off. This is because the high elasticity of TPE makes the material prone to breakage, and the pullback action causes the material to be stretched inside the nozzle, causing fracture problems.
• Printing speed: For the printing speed of TPE, it is recommended to control it at ≤30mm/s. This is due to the fact that the adhesion between the layers of the TPE material relies on a slow compaction process, and if the printing speed is too fast, the interlayer adhesion will be less than ideal.

Printability parameters of the TPU

• Temperature setting: The printing temperature range of TPU is generally between 200 – 240°C. If you encounter polyester-based TPU, you may have to turn the printing temperature up a little higher.
• Extruder Requirements: When printing TPU with a Bowden extruder, it is a good idea to add a spring-assisted feeder. This effectively reduces the resistance of the TPU material during the extrusion process, ensuring that the material can enter the nozzle smoothly.
• Layer height setting: When printing TPU, 0.2mm is usually the optimal layer height setting. This is because the smaller layer height reduces the peel stress between the layers, which in turn improves the strength and stability of the printed product.

Comparative analysis

1. Temperature differences: The extrusion temperature range of TPE is slightly lower than that of TPU, which may be related to the melting point and thermal stability of the TPE material. TPU, on the other hand, requires higher temperatures to fully melt and flow due to its unique molecular structure properties.
2. Extruder requirements: TPE and TPU have different requirements for extruders. TPE is highly elastic and require an all-metal hot end to prevent clogging; The TPU is recommended to be equipped with a spring-assisted feeder to reduce drag when using a Bowden extruder.
3. Printing speed and layer height: TPE has a slower printing speed and no special requirements for layer height setting; The TPU prints a bit faster, but the layer height setting has a big impact on its print quality and performance.

Which Has Superior Mechanical Performance?

In terms of mechanical properties, TPU and TPE have different performances, and TPU has obvious advantages in tear resistance, abrasion resistance, oil resistance, etc. Let’s break it down in detail.

Tear resistance

TPU has excellent tear resistance, with an aspect ratio of more than 500%, while TPEs typically have an aspect ratio of less than 300%. This means that the TPU can withstand harsher environments. For example, medical tubing has to go through 100,000 bending tests, and TPU can easily cope with this repeated stress due to its high tear resistance, showing super durability. In contrast, TPEs are a little less successful in this regard.

Abrasion resistance

From the Taber abrasion test results, the abrasion level of TPU is quite low, with less than 50mg per 1000 cycles, while TPE has an abrasion rate of more than 200mg per 1000 cycles. TPU’s excellent abrasion resistance makes it an excellent choice for outdoor gear, especially in high-wear applications such as hiking shoe fasteners. TPEs are not very useful in this type of scenario because they are not as good for abrasion resistance.

Oil resistance

Tested for oil resistance in accordance with ASTM D471, TPU has a volumetric expansion rate of less than 5% after 72 hours of immersion, indicating that it has excellent oil resistance. However, TPE is not good, as soon as it comes into contact with oil, it is easy to swell and even fail directly, which greatly limits the use of TPE in environments that require oil resistance. Therefore, if the use environment has oil resistance requirements, TPU is definitely a better choice.

In summary, TPU is significantly superior to TPE in terms of mechanical properties such as tear resistance, abrasion resistance and oil resistance.

What Are Their Cost & Sustainability Tradeoffs?

The cost and sustainability trade-offs between TPE and TPU are as follows:

1. Comparison of material costs

Cost items	TPE	TPU
Base price	$25-40/kg (with 30% recycled rubber)	$35-60/kg
Recycled materials reduce costs	15% cost reduction (requires closed-loop recycling system)	Recycling technology is immature (only 5% reuse)
Machining losses	Elastomers are easily deformed, resulting in 3-5% material waste	High toughness reduces debris generation (loss <1%)
Long-term maintenance costs	Frequent replacement (poor wear resistance)	Long-term use in a single molding (reduced replacement frequency)

Cost Equilibrium Point：

In terms of cost, TPE and TPU offer different advantages depending on the project cycle.

For short-term projects, i.e. projects lasting less than 1 year, the total cost of TPE can be reduced by 18 to 22 percent. This is because TPEs require relatively little upfront investment in material procurement and processing, so they can be cost-effective in the short term. For example, the packaging of some temporary promotional products can be made of TPE materials, which can save a lot of money in a short period of time.

This is not the case for long-term applications, where the project duration is more than 3 years. TPU surpasses in total cost of ownership thanks to its excellent durability benefits. While TPUs are more expensive to purchase upfront and consume more energy to produce, they are more cost-effective in the long run because they last longer, reducing replacement and repair costs. For example, for long-term outdoor use of protective equipment, TPU material is used, although the initial investment is more, but after many years of use, the overall cost is lower.

2. Environmental impact

Degradation characteristics

1. TPU: Bio-based TPU developed by BASF and other companies can be completely degraded in an industrial compost environment of 50-70°C after 180 days. However, once switched to home composting, the degradation effect is greatly reduced. This indicates that the degradation of bio-based TPU is demanding in terms of environmental conditions and requires the cooperation of specific industrial composting facilities.
2. TPE: Traditional petroleum-based TPEs degrade quite slowly, taking more than 50 years in marine environments. However, bio-based TPEs such as Arkema’s Rilsan® have significantly shortened degradation cycles, completing degradation in just 5 years, resulting in a significant improvement in degradation performance.

Carbon footprint

1. TPU production: The production of TPU consumes a lot of energy, with approximately 1.2 tons of CO2 emitted for every 1 ton of material produced. However, one bright spot for bio-based TPUs is that they can reduce their carbon footprint by 40%, which means that some of the carbon emissions can be offset to some extent. For example, some factories that use bio-based feedstocks to produce TPU reduce the pressure on the environment in this way.
2. TPE production: TPE production consumes relatively low energy and emits only 0.8 tons of CO2 per ton of material produced. However, in the process of recycled rubber, microplastic pollution is generated. Once these microplastics enter the natural environment, they are difficult to decompose and can cause long-term harm to the ecosystem.

Resource circulation

1. TPU recycling: With the help of chemical recycling technologies, such as Solvay’s Verradis process, TPU can be recycled to 85% of its original performance. This allows the recycled TPU material to also be used in applications where performance is critical.
2. TPE recycling: TPEs are mainly mechanically recycled, but this recycling method can reduce the performance of the material by 30% to 50%, resulting in the recycled TPE material can only be used to produce some low-end products, which greatly limits its application scope and value.

3. Decision-making matrix

Application scenarios	Preferred materials	Key considerations
Medical disposables	Bio-based TPU	Industrial compost biodegradable + biocompatible certification
Car weatherstrips	TPU	Weather resistance + maintenance-free for long-term use
Consumer electronics covers	TPE	Low initial cost + sufficient service life
Products of the marine environment	Bio-based TPEs	Although it degrades slowly, it can avoid the production of microplastics

How Do They Behave in Extreme Environments?

Low temperature environment (-40°C)

• ​TPE properties: At -40°C, TPE is highly brittle and often has a notched impact strength of less than 5kJ/m². Due to the hardening of its molecular structure and the sudden decrease in elasticity at low temperatures, the material becomes brittle, so it is not suitable for extremely cold outdoor equipment, such as polar research equipment.
• TPU performance: TPU is resilient even at temperatures as low as -40°C, with a notched impact strength of over 30kJ/m². Because its molecular chain has both hard segment strength and soft segment flexibility, it is widely used in outdoor, ski equipment and frozen food packaging.

Ultraviolet (UV) aging environment (500 hours)

• TPE performance: After 500 hours of UV aging, the TPE surface is prone to cracking, and the tensile strength loss is more than 40%. Because the unsaturated bonds in its molecular structure are easily damaged by ultraviolet rays and cause aging, it is not suitable for long-term exposure to the sun, such as outdoor furniture.
• TPU performance: TPU with carbon black has good UV resistance, with less than 10% strength loss after 500 hours of aging. Carbon black can absorb ultraviolet rays and protect molecular chains, making it suitable for outdoor products, automotive parts and other fields that are exposed to sunlight for a long time.

How to choose?

• When to choose TPE: TPE is the best choice if they are cost-sensitive and have a mild application environment where there are no extreme temperatures, strong UV rays and chemical contact. Such as interior decorations, disposable medical equipment, children’s toys, etc., can reduce costs and meet demand.
• When to choose TPU: TPU is preferred when the material needs to perform consistently in extreme temperatures, strong UV rays, chemicals, or high-abrasion environments. TPU performs well in complex working conditions such as outdoor equipment, sports equipment, automotive parts, industrial seals, etc.

What Are the Hidden Risks in Consumer Goods?

TPE and TPU materials in daily consumer products have hidden dangers such as chemical migration and performance degradation, which consumers and brands need to pay attention to.

Hidden dangers of TPE phone cases

• Plasticizer migration: Phthalates (e.g., DEHP) in TPE phone cases can leach 3-5 times more than the EU REACH limit (≤0.1%). Children may be at risk of endocrine disruption after biting. In 2024, German testing found that 42% of TPE phone case plasticizers exceeded the standard.
• Surface viscosity: Plasticizers (such as DOP) seep out, causing the surface of the phone case to “oil”. After 3 months of use, according to ASTM D1894, the coefficient of friction is increased by 40%, and it is easy to absorb dust and bacteria, and the number of colonies may exceed the standard of 200cfu/g.
• Thermal-oxygen aging: In summer, when the high temperature in the car exceeds 70°C, the TPE mobile phone case is easy to oxidize and embrittle. 55% impact strength attenuation at 3 months for poor durability.

Potential problems withTPU

1. Hydrolysis of TPU sports gear: Ester-based TPU is hydrolyzed faster at over 60°C and over 90% humidity. 42% reduction in tensile strength in 72 hours, yoga mat or cracking after 6 months of use in the tropics. 300% higher hydrolytic stability of ether-based TPUs, such as Lubrizol Estane®.
2. Microbial growth: TPU foam with a density of <0.3g/cm³ and an internal humidity of more than 85% is conducive to microbial growth. Malassezia grows up to 8 times faster than silica gel. > 0.5% nano silver ions or 5% bamboo charcoal powder can be added to prevent growth.
3. Stain migration: Dark-colored TPU armor, such as navy blue, has an issue with indigo dye migration. Co-wash with white sportswear and reduce colour fastness by grade 2 – 3 according to ISO 105 – C06 to stain white clothes.

Consumer purchase advice

• TPE products: Choose halogen-free flame retardant grades, such as Teknor Apex Medalist®, and avoid cheap recycled products that are prone to excessive VOCs. TPE phone cases should not be used for more than 8 months, and food contact cases should not be used for more than 3 months.
• TPU products: Ether-based TPU (hydrolyzed residue > 95%) for sports protective gear. Baby products are subject to USP Class VI biometric certification. Avoid contact with mothballs during storage to prevent accelerated aging.

Which Offers Better Post-Processing Options?

In terms of material post-processing, TPU has more abundant and practical options than TPE, so let’s compare TPE and TPU in detail from the two key dimensions of adhesion compatibility and surface treatment.

Adhesive compatibility

1.The case of TPEs:

• Bonding Method: When TPE is bonded, it can basically only be achieved by relying on cyanoacrylate, which is what we often call instant glue. For example, if you want to glue two small TPE objects together, you will most likely have to use this instant glue.
• Limitations: However, this bonding method is relatively simple, and in some scenarios with special requirements for bonding process, TPE is a bit “inadequate”. For example, in the manufacture of certain industrial products, where more complex and robust bonding methods are required, the simple bonding method of TPE is not sufficient, limiting its use in such applications.

2.Advantages of TPU:

• Bonding method: TPU has a lot of options in terms of bonding, among which hot compression welding is a very practical method.
• Hot press soldering conditions: When the temperature reaches 140°C and a pressure of 0.5MPa is applied, TPU can achieve very good results by hot press welding. Imagine that TPU materials can be firmly welded together on a production line in a factory with specific equipment and such temperature and pressure conditions.
• Advantages: The hot compression welding method is very strong and durable, and for those application scenarios that require high adhesive strength, such as manufacturing some high-strength outdoor equipment components, the advantages of TPU hot compression welding are highlighted, which can ensure that the product will not easily separate the adhesive during use.

Surface Finishing

1.Performance of TPEs:

Plasma treatment effect: After plasma treatment, TPEs do not perform well in terms of spray adhesion, often not even grade 1, and the coating is particularly prone to peeling. For example, if a decorative coating is applied to the surface of a TPE product, it may not be long before the coating begins to peel off, affecting the appearance and use of the product.

Limitations: This makes it difficult for TPE to be useful in applications where high quality surface coatings are required or where delicate decoration is required. For example, if high-end electronic product shells are made of TPE, after plasma treatment, the surface coating cannot meet the high quality requirements.

2.The TPU excels:

• UV coating: TPU can be UV coated and can meet ASTM D3359 Class 4B standards for adhesion. This means that the UV coating adheres well to the TPU surface.
• Advantages: UV coating brings many benefits to TPU, not only improving the surface hardness of TPU, making it more wear-resistant, and extending product life; It also makes TPU products look more aesthetically pleasing, while enhancing their weatherability and keeping them in good condition in different climates. Like some outdoor sports equipment, it is made of UV-coated TPU material, which is both beautiful and durable, and is ideal for applications that require high-quality surface decoration and protection.

In summary, TPU offers a better option for post-processing, both in terms of adhesive compatibility and surface finish.

TPE vs TPU: How to Choose

When choosing TPE (thermoplastic elastomer) and TPU (thermoplastic polyurethane), the following key factors need to be considered comprehensively to match specific application scenarios and needs:

Factor	TPE advantages	TPU advantages
Mechanical properties	Low strength, low wear resistance	High strength, high abrasion resistance, tear resistance
Temperature resistance	Embrasile-making at -40 °C	Stable from -40°C to +120°C
Chemical resistance	weak	Strong (oil and solvent resistant)
Bonding method	Cyanoacrylate	Hot-pressed welding, multiple bonding
Surface treatment	Low spray adhesion	UV coating, high adhesion
cost	Low ($25-40/kg)	Height ($35-60/kg)
Eco-friendliness	Long degradation cycle	Biodegradable version is optional
Medical applications	Hypoallergenic and flexible	Anticoagulant, high creep resistance

Select Recommendations

• Choose TPE: Low cost, softness, low allergenicity needs, mild environment (e.g., toys, indoor products).
• Choose TPU: High strength, abrasion resistance, chemical resistance, tear resistance requirements, or extreme environments (e.g., outdoor equipment, medical devices).

Conclusion

TPE and TPU each have their own unique properties and application areas. When choosing which material is better, you need to consider multiple factors such as specific application scenarios, performance requirements, cost budget, and environmental protection requirements. If you pursue low cost, high elasticity and softness, and do not need particularly high wear resistance and oil resistance, then TPE may be a better choice; if you pursue high wear resistance, oil resistance and transparency, and are willing to bear higher costs, then TPU may be more suitable. In addition, you also need to pay attention to the environmental protection and sustainability of the material to ensure that the selected material meets the environmental protection requirements of modern society.

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Team LS

This article was written by various LS contributors. LS is a leading resource on manufacturing with CNC machining, sheet metal fabrication, 3D printing, injection molding,metal stamping and more.

FAQs

1. What are the disadvantages of TPU?

Although TPU (thermoplastic polyurethane) has many excellent properties, such as good elasticity, wear resistance, oil resistance, etc., it also has some disadvantages. For example, TPU has a narrow processing temperature range, which makes it easy to stick to the mold during processing, and has high requirements for processing equipment. In addition, TPU has relatively poor hydrolysis resistance, and prolonged exposure to water or moisture may cause its performance to deteriorate.

2.Is TPE 83A softer than TPU 95A?

Yes, TPE 83A is softer than TPU 95A. Hardness is an important property indicator of a material and is often used to express the ability of a material to resist compression set. In terms of hardness, a lower number means that the material is softer, and a higher number means that the material is harder. Therefore, the hardness of TPE 83A is lower than that of TPU 95A, so TPE 83A is relatively soft.

3. What are the benefits of TPE filament?

TPE filaments offer a variety of advantages. First of all, TPE filament yarn has good elasticity and flexibility, which can adapt to various complex shapes and bending requirements. Secondly, TPE filament yarn has excellent processing properties and can be made into various products through extrusion, injection molding and other processing processes. In addition, TPE filament yarn also has the characteristics of environmental protection, non-toxicity and tastelessness, which meets the needs of modern people for environmentally friendly materials.

4. Does TPE decompose?

TPEs (thermoplastic elastomers) can decompose under certain conditions. Although TPEs are thermoplastic and can be processed and used repeatedly, under the action of environmental factors such as high temperature, oxygen, and ultraviolet rays, the molecular chain of TPEs may break, resulting in a decrease in its properties or even decomposition. Therefore, when using and storing TPE materials, care needs to be taken to avoid prolonged exposure to high temperatures or strong ultraviolet rays to prolong their service life.