TPV, TPR, TPU, and TPE Injection Molding

TPE Injection Molding (Thermoplastic Elastomer)

TPE is a special polymer material containing both rubber and plastic phases, combining the elasticity of rubber with the plasticity of plastic. TPE injection molding materials retain rubber’s high elasticity, aging resistance and oil resistance while maintaining plastic’s easy processability. They can be processed through various methods like injection molding, extrusion, and blow molding. Sprue and scrap materials can be 100% directly reused after crushing, reducing processing costs.

Advantages of TPE Injection Molding Material:

• Excellent softness and resilience
• Recyclable and environmentally friendly
• Simple processing (no vulcanization required)
• Can be colored, bonded, or overmolded (e.g., with PP or ABS)

Disadvantages TPE Injection Molding Material:

• Poor high-temperature resistance (generally <80°C)
• Average oil and chemical resistance
• Mechanical strength lower than TPU or TPV

Applications TPE Injection Molding Material:

• Daily necessities (toothbrush handles, bottle cap liners)
• Electronic products (phone cases, earphone covers)
• Automotive parts (soft-touch interior components)

TPR (Thermoplastic Rubber)

TPR is a thermoplastic rubber originally synthesized by mixing SBS with oil and heating. It combines rubber characteristics with thermoplasticity and is widely used in footwear, toys and other fields. Although SEBS-based blend materials with better performance have emerged through material development, Chinese manufacturers still conventionally refer to SBS modified blends as TPR for differentiation purposes.

Advantages:

• Soft touch similar to rubber
• Easy processing (injection molding, extrusion)
• Lower cost than silicone and TPU

Disadvantages:

• Poor temperature resistance (long-term use <70°C)
• Prone to aging with average weather resistance
• Inferior oil and wear resistance compared to TPU

Applications:

• Footwear materials (soles, insoles)
• Toys (soft rubber figurines)
• Tool handles (non-slip grips)

TPU (Thermoplastic Polyurethane)

TPU is a material polymerized through the reaction of diisocyanate molecules with macromolecular polyols and low molecular polyols. Divided into polyester and polyether types, TPU features excellent elasticity and wear resistance, making it widely used in sports equipment, automotive components and other fields. TPU has a broad hardness range, from very soft rubber-like to very hard plastic-like.

Advantages:

• Extremely high wear and tear resistance
• Oil and solvent resistance (better than TPE/TPR)
• Wide hardness range (Shore 60A-80D)
• Can be transparent or colored

Disadvantages:

• Higher processing temperatures (180-220°C)
• Strong water absorption requiring pre-drying
• Higher cost than TPE/TPR

Applications:

• Industrial components (hydraulic seals, conveyor belts)
• Sports equipment (ski boots, diving gear)
• Electronic products (smartwatch bands)

TPV (Thermoplastic Vulcanizate)

TPV is a thermoplastic vulcanized rubber formed by blending thermoplastic plastics with rubber. In TPV, the rubber phase exists as vulcanized microparticles while the plastic phase serves as the continuous phase. TPV combines vulcanized rubber’s heat resistance and low compression set properties with superior processing characteristics of thermoplastics, allowing processing through injection, extrusion and other thermoplastic methods. TPV features wide soft-hardness applications, easy coloring, and is environmentally friendly and recyclable.

Advantages:

• High temperature resistance (-40°C to 120°C)
• Excellent weather and aging resistance
• Recyclable and more eco-friendly than traditional rubber

Disadvantages:

• Higher price than TPE/TPR
• Limited hardness options (typically harder)
• Requires higher injection pressure for processing

Applications:

• Automotive sealing strips, wiper blades
• Building waterproofing materials
• Industrial weather-resistant seals

Comparison Table of TPV, TPR, TPU, and TPE Injection Molding

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