Thermoplastic Polyurethane (TPU)
Material Introduction
Thermoplastic Polyurethane (TPU) is a flexible, abrasion-resistant, and highly elastic polymer widely used in additive manufacturing for functional prototypes and end-use components. Known for its rubber-like behavior combined with thermoplastic processability, TPU enables the production of parts that require impact absorption, vibration damping, and bendability. Its excellent layer adhesion and resilience make it ideal for components subjected to repeated loading or mechanical deformation. When processed through advanced polymer additive manufacturing workflows such as those available in Neway AeroTech’s dedicated TPU 3D printing, TPU offers consistent mechanical behavior, good surface finish, and geometric freedom. Its chemical resistance and durable performance in harsh environments make it common in consumer products, aerospace interiors, robotics, industrial seals, medical device housings, and automotive components.
International Names or Representative Grades
Region | Common Name | Representative Grades |
|---|---|---|
USA | TPU | TPU 85A, TPU 95A |
Europe | Thermoplastic Polyurethane | Elastollan®, Desmopan® |
Japan | Polyurethane Elastomer | TPU-A |
China | 热塑性聚氨酯 | TPU 90A |
Industry Classification | Flexible Thermoplastic Elastomer | TPU-E, TPU-S |
Alternative Material Options
Several polymers can be used as alternatives to TPU when different mechanical or environmental properties are required. For rigid structural parts, polycarbonate (PC) offers much higher strength and improved temperature resistance. When chemical stability and overall toughness are needed, nylon provides superior wear resistance. Applications requiring maximum flexibility may benefit from flexible resin used in SLA-based systems, which can deliver softer elastomeric properties. For durable functional prototypes with enhanced impact resistance, tough resin provides a balanced alternative. If transparency is required, PETG offers good clarity and weatherability. For lightweight printed parts with excellent environmental adaptability, ABS is a proven solution across general engineering applications.
Design Purpose
TPU was originally engineered to bridge the gap between flexible rubber-like elastomers and melt-processable thermoplastics. Its design intent focuses on combining elasticity, tear resistance, and chemical stability with efficient thermal processing. In additive manufacturing, TPU was adopted to enable durable, flexible components with repeatable performance for cushioning, sealing, and dynamic applications. The versatility of TPU enables engineers to create soft-touch surfaces, dynamic joints, flexible ducts, wearable devices, and shock-absorbing structures with complex geometries that would be extremely difficult or impossible to mold using traditional methods.
Chemical Composition (Generic TPU)
Component | Composition (%) |
|---|---|
Polyols | 50–70 |
Diisocyanates | 20–40 |
Chain Extenders | 5–15 |
Additives (stabilizers, colorants) | < 5 |
Physical Properties
Property | Value |
|---|---|
Density | 1.10–1.22 g/cm³ |
Melting Point | 160–220°C |
Shore Hardness | 80A–98A |
Water Absorption | Low |
Thermal Conductivity | Moderate |
Mechanical Properties
Property | Typical Value |
|---|---|
Tensile Strength | 25–50 MPa |
Elongation at Break | 300–600% |
Tear Strength | High |
Abrasion Resistance | Excellent |
Flexural Modulus | Low (high flexibility) |
Key Material Characteristics
Outstanding flexibility with excellent elastic recovery after repeated bending
High tear resistance and exceptional abrasion durability for moving components
Strong impact absorption and vibration-damping properties are ideal for protective structures
Good chemical resistance to oils, fuels, and cleaning agents
Excellent fatigue performance for dynamic and wearable applications
Smooth surface finish and strong interlayer bonding during 3D printing
Ability to form complex, flexible geometries is impossible with traditional molding
Consistent behavior across a wide temperature range
Soft-touch feel is suitable for consumers and ergonomic components
Colorability and good aesthetic adaptability for industrial design
Resistant to microcracking under cyclic deformation
Suitable for both prototypes and end-use elastomeric parts
Manufacturability in Different Processes
FDM/FFF 3D printing: TPU prints reliably at lower temperature ranges, with strong interlayer adhesion, making it ideal for soft, bendable components.
SLS: Powder-based TPU enables uniform density and superior mechanical consistency for industrial-grade flexible parts.
SLA/DLP elastomer alternatives: Although not used directly, TPU-like flexible resins can complement applications requiring finer detail.
CNC machining: Limited due to elasticity and low modulus, though feasible for trimming and finishing soft components.
Injection molding (traditional): TPU can be molded but lacks the geometric freedom and low-volume advantages of additive manufacturing.
Assembly and bonding: TPU is compatible with mechanical fastening and selective adhesive bonding for hybrid assemblies.
Prototyping: TPU integrates well with mixed-material rapid prototyping workflows offered through Neway’s 3D printing services.
Suitable Post-Processing Methods
Surface smoothing through controlled heat exposure or chemical treatment
Trimming and cutting for precision edge refinement
Dyeing and pigmentation for aesthetic customization
Surface sealing to reduce porosity and improve chemical resistance
Elasticity tuning through controlled thermal cycles
Support removal for FDM/SLS structures
Dimensional calibration and compression testing through material testing workflows
Packaging and sterilization options for medical or wearable components
Common Industries and Applications
Consumer electronics: protective cases, wearable device straps, soft-touch components
Automotive: flexible ducts, seals, gaskets, vibration-reducing components
Aerospace interiors: cushioning structures, flexible connectors, cabin components
Robotics: flexible joints, compliant grippers, dynamic housings
Medical devices: braces, padding elements, ergonomic handles
Industrial products: wheels, rollers, polyurethane bushings, anti-vibration mounts
When to Choose This Material
When the design requires high flexibility, elastic recovery, or energy absorption
When the part will undergo dynamic loading or repeated mechanical movement
When soft-touch or ergonomic characteristics are essential
When complex flexible geometries cannot be molded conventionally
When chemical resistance to oils, fuels, sweat, or solvents is required
When lightweight, resilient components must be produced with low tooling cost
When multi-material integration or wearable function is needed
When product prototypes must replicate rubber-like performance
