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How to Choose TPU: A Complete TPU Selection Guide

Thermoplastic Polyurethane (TPU) is one of the most versatile elastomers used in modern manufacturing. With its excellent abrasion resistance, flexibility, and durability, TPU is widely applied in footwear, automotive, electronics, medical devices, and industrial products.

However, TPU is not a single material. Different chemistries, hardness levels, and processing grades mean that selecting the right TPU can significantly impact product performance and cost. This guide explains the key factors to consider when choosing TPU material.

1. Understand the Application Requirements

The first step in TPU selection is defining the application environment and performance expectations.

Ask these questions:

• Will the product face mechanical stress or abrasion?

• Is flexibility or softness the priority?

• Will the material be exposed to oils, chemicals, or UV light?

• Does the application require transparency or color stability?

• Is long-term durability critical?

Clear application requirements help narrow down TPU type and formulation.

2. Choose the Right TPU Chemistry

Different TPU chemistries provide different performance advantages.

Polyester TPU

Best for: abrasion resistance and mechanical strength

High durability

Strong tear and tensile strength

Good oil and chemical resistance

Common in footwear soles and industrial parts.

Polyether TPU

Best for: hydrolysis resistance and flexibility

Excellent water and microbial resistance

Superior low-temperature performance

Better long-term elasticity

Ideal for cables, outdoor products, and medical applications.

3. Select the Proper Hardness

TPU hardness typically ranges from 60A to 75D, offering design flexibility.

Soft TPU (60A–85A)   

High flexibility and comfort

Soft touch and elasticity
Used in wearables, soft grips, and flexible tubing

Medium TPU (90A–98A)

Balanced flexibility and strength
Common in footwear and consumer goods

Hard TPU (50D–75D)

High rigidity and load-bearing performance
Suitable for industrial parts and structural components

4. Consider Processing Methods

Processing compatibility is critical for efficient production.

Injection Molding TPU

Requires good flow and thermal stability

Suitable for complex shapes

Widely used in footwear and consumer products

Extrusion TPU

Requires stable melt strength
Used in tubing, films, and cable jackets

Foaming TPU

Lightweight and resilient
Popular in athletic footwear midsoles

Film & Sheet TPU

Requires clarity and flexibility
Used in protective films and laminations

Selecting a TPU grade designed for the specific process improves productivity and product quality.

5. Evaluate Mechanical and Chemical Performance

Depending on the application, consider:

• Abrasion resistance

• Tear strength

• Elastic recovery

• Chemical and oil resistance

• Hydrolysis resistance

• UV resistance

For harsh environments, prioritize durability and resistance properties.

6. Balance Cost and Performance

While high-performance TPU grades offer superior durability, they may increase material costs. In many applications, a balanced formulation provides sufficient performance at a competitive price.

To optimize cost:

• Avoid over-specifying properties

• Match TPU grade with real performance needs

• Work with suppliers to customize formulations

7. Check Sustainability and Compliance

More industries now require environmentally friendly materials and regulatory compliance.

Consider:

• Recyclability

• Bio-based TPU options

• REACH / RoHS compliance

• Medical or food-contact certifications

Sustainable TPU solutions can enhance brand value and meet market regulations.

Conclusion

Choosing the right TPU involves evaluating application requirements, chemistry, hardness, processing methods, and performance needs. Polyester TPU offers strength and durability, polyether TPU provides flexibility and hydrolysis resistance, and aliphatic TPU ensures UV stability and aesthetic performance.

By aligning material properties with product requirements, manufacturers can achieve optimal performance, cost efficiency, and product longevity.