TPE: What Is a Thermoplastic Elastomer and How It Is Used

TPE (Thermoplastic Elastomer) is a class of polymer materials that combines the elastic properties of rubber with the processability of thermoplastics.
Thanks to this unique combination, TPEs are increasingly used in sectors such as automotive, electronics, consumer goods, medical applications, and 3D printing.
These materials enable the production of flexible, durable and recyclable components, while also offering ease of processing and competitive costs.
What is TPE
TPE is a thermoplastic elastomer, meaning a material that exhibits rubber-like elastic behaviour but can be melted and reshaped like a plastic.
Unlike traditional vulcanised rubber:
it does not require irreversible chemical processes
it can be remelted and reused
it can be processed using standard industrial methods
This makes it highly versatile and well suited to modern industrial manufacturing.
Structure of TPEs
TPEs are made up of two different polymeric phases:
an elastic phase (rubber), which provides flexibility
a thermoplastic phase, which gives stability and processability
This structure allows the material to:
deform elastically
recover its original shape
be processed through melting
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Main Properties of TPE
TPEs offer a well-balanced combination of properties:
Elasticity
They can deform and return to their original shape without permanent damage.
Flexibility
They remain flexible even at low temperatures.
Good impact resistance
They absorb energy without breaking easily.
Grip and adhesion
Ideal for non-slip surfaces and ergonomic handles.
Recyclability
As thermoplastics, they can be remelted and reused.
Good processability
They can be processed through:
injection moulding
extrusion
3D printing
overmoulding
Types of TPE
The TPE family includes several materials, such as:
TPE-S (Styrene-based TPE)
Among the most common, used in consumer products and automotive applications.
TPE-O (Olefinic TPE)
Used in applications requiring weather resistance.
TPE-V (Thermoplastic vulcanisates)
Offer performance similar to vulcanised rubber.
TPE-E (Copolyester elastomers)
Provide good chemical and thermal resistance.
TPE-U
Includes thermoplastic polyurethanes (TPU), a subcategory with higher performance.
TPE Hardness
TPEs are available in a wide range of Shore hardness levels, which determine material rigidity.
Indicatively:
Shore A 20–40 → very soft
Shore A 50–70 → medium flexibility
Shore A 80–95 → more rigid
This allows the material to be adapted to many different applications.
Applications of TPE
Thanks to their versatility, TPEs are used across many industries.
Automotive
seals
coatings
anti-vibration components
Electronics
cables and coatings
flexible connectors
Consumer goods
ergonomic grips
sports equipment
soft-touch products
Medical
flexible devices
medical tubing
Packaging
elastic components
caps and closures
TPE in 3D printing
TPEs are also used in MJF and FDM 3D printing, especially when flexible parts are required.
Advantages
high flexibility
good impact resistance
vibration absorption
In many cases, TPU - a variant within the TPE family - is preferred due to its greater stability during printing.
Advantages of TPEs over traditional rubber
TPEs are gradually replacing some vulcanised rubbers because they offer:
simpler production processes
recyclability
reduced waste
overmoulding capability
lower production costs
Conclusions
TPE is an extremely versatile material that combines the flexibility of rubber with the processability of thermoplastic polymers.
Thanks to its elasticity, durability and recyclability, it is widely used across numerous industrial sectors and everyday products.
With the evolution of manufacturing processes and 3D printing, TPEs will continue to play an increasingly important role in the design of flexible and functional components.
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FAQ
What type of material is TPE?
TPE (thermoplastic elastomer) is a family of plastic materials that combines the properties of rubber (elasticity, flexibility) with those of thermoplastics (ease of processing and recyclability).
In practice:
It is soft and flexible like rubber
It can be moulded and remelted like a plastic
It does not require vulcanisation (unlike traditional rubber)
It is widely used in:
industrial components
seals
ergonomic products
3D printing (especially powder or filament-based)
What is the difference between TPE and TPU?
TPU (thermoplastic polyurethane) is actually a subcategory of TPE, but with more specific characteristics.
Main differences:
TPE → more general, softer and more versatile
TPU → stronger, more elastic and more durable
In detail:
TPU has higher resistance to abrasion and chemicals
TPE is often easier to process and more cost-effective
TPU maintains its shape better under stress
Summary:
TPE = softer and more versatile
TPU = more technical and higher performance
What is the difference between PVC and TPE?
PVC (polyvinyl chloride) is a traditional plastic, whereas TPE is a more modern elastomer.
Key differences:
TPE
more environmentally friendly (free from chlorine and problematic plasticisers)
softer and more flexible
better tactile feel
PVC
more rigid or semi-flexible
often contains plasticisers
less recyclable and less sustainable
In many sectors, TPE is replacing PVC for both environmental and performance reasons.
Is TPE suitable for 3D printing?
Yes, TPE is widely used in 3D printing, both:
as filament (FDM) for flexible parts
as powder (MJF) for more complex technical components
It enables the production of:
elastic parts
seals
ergonomic components
functional prototypes