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Thermoplastic Vulcanizate (TPV)

Thermoplastic Vulcanizate (TPV) Overview

Thermoplastic Vulcanizate (TPV) is a high-performance elastomeric alloy offering the flexibility, resilience, and compression set resistance of thermoset rubber with the processing efficiency and recyclability of thermoplastics. Built on a foundation of crosslinked ethylene propylene diene monomer (EPDM) rubber particles dispersed in a polypropylene (PP) matrix, TPV was first commercialized under the Santoprene name by Monsanto in 1977. It has since become the global benchmark for engineered thermoplastic elastomers in demanding applications where sealing performance, flex fatigue resistance, and long-term durability are required.

As a TPV resin supplier, Formerra provides access to Celanese Santoprene thermoplastic vulcanizate grades spanning the full Shore 35A to 50D hardness range, with formulations optimized for automotive, medical, building and construction, industrial, and consumer goods applications.

TPV is produced through dynamic vulcanization: EPDM rubber and polypropylene are melt-blended in a twin-screw extruder while a curing agent crosslinks the rubber phase simultaneously. The result is fully crosslinked EPDM rubber particles averaging 1-5 micrometers in diameter, uniformly dispersed throughout a continuous PP matrix. The crosslinked rubber particles deliver elastic recovery, compression set resistance, and high-temperature stability. The PP matrix provides melt processability and chemical resistance. This two-phase microstructure is what separates TPV from non-vulcanized thermoplastic elastomer blends and enables its superior rubber-like functional performance.

pyramid

TPV Types and Grades

TPV materials are available in these grades, with formulations tailored to Shore hardness requirements, processing method, end-use regulatory compliance, and OEM qualification specifications.

Compression set resistance is the defining performance advantage of TPV over non-vulcanized thermoplastic elastomers. The crosslinked EPDM rubber phase prevents permanent deformation under sustained compressive load. Standard Santoprene TPV delivers compression set values of 25-50% (22 hours at 70°C, ASTM D395 Method B), which approaches thermoset EPDM vulcanizate performance and significantly outperforms SEBS-based TPE compounds, which typically show 50-80% compression set under equivalent conditions. This performance is critical for weatherstripping, gaskets, and seals where maintaining contact force over years of service determines functional life. Temperature performance spans a range suitable for demanding automotive and outdoor applications. TPV maintains flexibility and elastic recovery from -50°C to 135°C for standard grades, with heat-stabilized formulations performing to 150°C. The EPDM rubber phase resists thermal oxidation, ozone attack, and UV degradation, making TPV the preferred material for automotive weatherstripping facing full seasonal temperature cycles and years of outdoor exposure.

Chemical resistance reflects the EPDM rubber and PP matrix composition. TPV shows excellent resistance to dilute acids, alkalis, water, steam, brake fluids, and polar solvents. Ozone resistance is outstanding, with no cracking under ASTM D1149 exposure conditions. UV resistance is strong due to the saturated backbone of the EPDM phase. Standard grades swell in petroleum-based hydrocarbons and mineral oils. Fluid-resistant grades in the Celanese portfolio address these applications.

Standard General Purpose

Broad hardness range (Shore 35A to 50D) for injection molding, extrusion, and blow molding. Balances rubber-like performance with processing efficiency. Used across automotive, industrial, and consumer applications.

Automotive Sealing

Grades optimized for weatherstrip extrusion and automotive seal applications. Enhanced compression set, surface quality, and co-extrusion compatibility with rigid PP substrates. Meets major OEM automotive specifications.

Medical / Food Contact

USP Class VI and ISO 10993-compliant grades for medical tubing, syringe plunger tips, and pharmaceutical fluid contact. Controlled extractables and validated biocompatibility.

UV / Heat Stabilized

Enhanced stabilizer packages for extended outdoor service and elevated continuous-temperature applications. Used in construction seals, roofing profiles, and outdoor consumer goods.

Fluid Resistant

Grades with enhanced resistance to automotive fluids, mineral oils, and lubricants. Used for under-hood hoses, grommets, and fluid-handling components where standard EPDM/PP grades swell.

Colorable / Natural

Natural or lightly pigmented formulations for applications requiring custom color at the press or visual inspection capability. Used in medical and consumer applications.

Performance Characteristics

Mechanical Properties

Mechanical Properties

Tensile strength

3-10 MPa (Shore 35A to 50D range)

Elongation at break

200-600%

Compression set

25-50% (22 h at 70°C), 50-70% (22 h at 100°C)

Tear strength

10-40 N/mm

Hardness range

Shore 35A to Shore 50D

Flexural modulus

5-100 MPa (hardness dependent)

Thermal Properties

Thermal Properties

Service temperature range

-50°C to 135°C (standard), -40°C to 150°C (heat-stabilized)

Heat deflection temperature

45-80°C at 0.46 MPa (hardness dependent)

PP matrix melting point

165-170°C

Processing temperature range

190-230°C

Coefficient of linear thermal expansion

130-200 x 10-6 /°C

Operating Environment

Operating Environment

Water absorption

0.1-0.3% in 24 h at 23°C. TPV absorbs very little moisture due to the hydrophobic PP matrix and EPDM rubber content. Dimensional stability in wet environments is excellent. Pre-drying is recommended before processing (80°C for 2 hours), though moisture sensitivity is lower than nylon or TPU. Parts maintain sealing performance and dimensions in outdoor applications exposed to rain, humidity, and condensation.

UV/weatherability rating

Excellent. The saturated backbone of the EPDM rubber phase provides inherent UV and ozone resistance without sacrificial stabilizer depletion. Standard grades with carbon black reinforcement deliver the highest UV stability. UV-stabilized grades without carbon black maintain light colors outdoors for extended service. Automotive weatherstrip applications demonstrate 10+ years of outdoor durability under full weathering exposure.

Hydrolysis resistance

Excellent. TPV shows outstanding resistance to hydrolysis in hot water, steam, and high-humidity environments. The EPDM rubber and PP matrix both resist hydrolytic attack, making TPV suitable for steam sterilization (medical grades), hot water exposure, and continuous wet-contact applications. This performance distinguishes TPV from polyester-based elastomers, which hydrolyze under prolonged hot water contact.

Stress cracking sensitivity

Very low. The elastic nature of TPV accommodates stress through deformation rather than crack initiation. No significant environmental stress cracking occurs in typical service environments. Contact with aromatic hydrocarbons causes swelling rather than cracking. Sharp stress concentrations are far less critical than in rigid thermoplastics due to the material's rubber-like elastic deformation response.

Electrical Properties

Electrical Properties

Dielectric strength

10-20 kV/mm

Dielectric constant

3.5-5.0 at 1 MHz

Volume resistivity

10^12-10^14 Ohm-cm

Surface resistivity

10^12-10^14 Ohm

Physical Properties

Physical Properties

Density

0.87-1.05 g/cm³ (unfilled, hardness dependent)

Melt flow index (MFI)

0.5-30 g/10 min (230°C / 2.16 kg, grade dependent)

Mold shrinkage

1.5-3.0% (varies with hardness and processing)

Rebound resilience

30-55%

Chemical Resistance

Chemical Resistance

Excellent resistance

Dilute acids, dilute alkalis, water, steam, ozone, UV, brake fluids (glycol-based), alcohols, glycols

Good resistance

Concentrated polar solvents, ethylene glycol, many industrial lubricants

Limited resistance

Aliphatic hydrocarbons (swelling), aromatic hydrocarbons (toluene, xylene), mineral oils in standard grades

Poor resistance

Concentrated hydrocarbons, chlorinated solvents, aromatic oils at elevated temperatures

Note

TPV offers substantially better heat and UV resistance than SBS or SEBS-based TPE compounds. Chemical resistance to water, steam, and polar solvents is broadly comparable to thermoset EPDM vulcanizate. Fluid-resistant grades (Geolast from Celanese) address hydrocarbon-contact applications.

Strengths, Weaknesses, and Operating Limits

Key Strengths

  • Thermoset Rubber Performance with Thermoplastic Processing: TPV delivers compression set, flex fatigue resistance, and sealing performance approaching thermoset EPDM vulcanizate, without the cure step, secondary tooling costs, or unrecyclable scrap of thermoset processing. Compression set values of 25-50% at 70°C meet most automotive weatherstripping and appliance seal specifications. This combination eliminates the processing inefficiencies of thermoset rubber while maintaining the functional performance sealing and vibration applications demand.
  • Outstanding Flex Fatigue Resistance: TPV withstands millions of flex cycles without degradation, outperforming most TPE families in dynamic applications. This durability is critical for peristaltic pump tubing, bellows, weatherstripping under repeated door closing, and accordion-style flexible connectors. The crosslinked EPDM rubber phase accommodates cyclic deformation without crack propagation, delivering service life measured in years for demanding dynamic applications.
  • Wide Hardness Range from a Single Material Family: Shore hardness from 35A to 50D spans the full spectrum from very soft formulations to semi-rigid compounds within a single material chemistry. This range covers soft-touch grips and gasketing (Shore 40-60A), structural sealing profiles (Shore 60-80A), and rigid-flex components (Shore 50D). A single material family simplifies inventory management and allows overmolding between different hardness grades for integrated designs.
  • Recyclability vs. Thermoset Rubber: TPV granules process as thermoplastics and are fully recyclable through in-process regrind and end-of-life mechanical recycling. Thermoset rubber cannot be recycled once cured. This recyclability supports sustainability goals, enables scrap return programs, and simplifies manufacturing waste management. For automotive OEMs with end-of-life vehicle recyclability targets, TPV weatherstripping and seals contribute positively to recyclability calculations.
  • Superior UV and Ozone Resistance: The saturated EPDM backbone resists ozone cracking and UV degradation that would rapidly deteriorate polybutadiene or unsaturated rubber-based compounds. TPV maintains appearance and physical properties through outdoor weathering tests exceeding 10 years for automotive weatherstripping applications. This UV and ozone stability eliminates the antiozonant compounds required in thermoset rubber formulations, reducing chemical complexity in the finished part.
  • Strong PP Adhesion in Co-extrusion and Overmolding: TPV adheres directly to polypropylene and TPO substrates through two-shot molding and co-extrusion without adhesives. The PP-based matrix in TPV develops strong interfacial adhesion to PP and PP-based substrates, enabling integrated seal-substrate assemblies for automotive door seals and window encapsulations. This compatibility eliminates the bonding steps required with non-compatible rubber-plastic combinations and reduces assembly cost.

Known Weaknesses

  • Limited Resistance to Petroleum Hydrocarbons: Standard TPV grades swell in contact with petroleum oils, fuels, and aromatic hydrocarbons. Fuel system components, oil-contact seals, and parts in direct hydrocarbon service require specialty fluid-resistant grades (Geolast from Celanese) or alternative materials. Standard Santoprene grades are not suitable for fuel contact or continuous mineral oil immersion.
  • Compression Set Above Thermoset EPDM: While TPV outperforms non-vulcanized TPEs, compression set values of 25-50% at 70°C still exceed the best thermoset EPDM rubber formulations (10-20%). Critical static sealing applications requiring minimal stress relaxation over very long service intervals should confirm grade-specific compression set data against application requirements. Specialty low-compression-set Santoprene grades address the most demanding sealing specifications.
  • Moderate Maximum Service Temperature: The PP matrix limits continuous service temperature to 135°C for standard grades. Applications requiring sustained temperatures above 135°C need specialty high-temperature formulations or alternative materials. Short-duration excursions above 150°C cause permanent set and dimensional change. Under-hood automotive applications near high-heat powertrain components require careful grade selection and thermal validation.
  • High Mold Shrinkage Complexity: Shrinkage of 1.5-3.0% is significantly higher than rigid thermoplastics and varies with part thickness, processing conditions, and Shore hardness. Soft grades show higher shrinkage than harder formulations. This variability complicates tool design for parts requiring tight dimensional tolerances. Close coordination between material supplier, molder, and tool designer is necessary to achieve dimensional targets on complex sealing profiles.
  • Processing Sensitivity for Soft Grades: Grades below Shore 50A require more careful demolding strategies than rigid thermoplastics. Low mold temperatures, generous draft angles, and smooth mold surfaces reduce demolding forces. Cycle times for soft grades extend due to longer cooling requirements for adequate green strength at ejection. These factors increase process complexity compared to standard thermoplastic molding operations.

Operating Limits

  • Temperature Range: Continuous use temperature of -50°C to 135°C for standard grades and -40°C to 150°C for heat-stabilized grades defines the service envelope. The PP matrix melting point (165-170°C) defines the absolute upper processing limit. Short-duration excursions above 150°C cause permanent set in standard grades. At the lower extreme, flexibility and impact resistance are maintained to -50°C for standard formulations, making TPV suitable for arctic and cold-climate outdoor applications without grade changes.
  • Chemical Environment: Avoid contact with petroleum fuels, mineral oils, aromatic hydrocarbons, and chlorinated solvents in standard grades. These fluids cause swelling and mechanical property reduction. Specialty fluid-resistant grades (Geolast) extend the chemical envelope for hydrocarbon-contact applications. Ozone, UV, dilute acids, alkalis, water, steam, glycol brake fluids, and alcohols are all compatible with standard Santoprene grades. Cleaning with soap and water or isopropyl alcohol is safe.
  • Mechanical Stress and Loading: Avoid sustained compressive strains exceeding 25-30% in critical sealing applications to maintain adequate sealing force over product life. Dynamic applications benefit from TPV's outstanding fatigue resistance, and flex life is seldom a limiting factor. Static applications must confirm compression set at application temperature and duration. Wall thickness of 1.0-3.0 mm applies for most injection-molded parts. Sections below 1.0 mm require high-flow grades and optimized gating. Exceptionally soft grades (Shore 35-50A) need generous radii and robust ejection design due to material compliance.

Typical Applications

  • Automotive weatherstripping and door seals requiring compression set resistance and long-term UV stability
  • Under-hood grommets, plugs, and vibration isolators requiring heat and fluid resistance
  • Automotive window encapsulation using co-extruded TPV with rigid PP frames
  • Medical tubing for peristaltic pumps, IV sets, and pharmaceutical fluid transfer using USP Class VI grades
     
  • Wire and cable jacketing for flexible and outdoor electrical applications
  • Construction sealing profiles and expansion joints for window and curtainwall systems
  • Appliance door gaskets and seals requiring flex fatigue resistance and heat compatibility
  • Consumer goods grips, handles, and soft-touch overmolded components
  • Industrial hoses, bellows, and accordion-style flexible connectors
  • Syringe plunger tips and medical closures using biocompatible TPV grades

Niche Applications

  • EV battery coolant system hoses requiring fluid resistance and long flex life
  • Peristaltic pump tubing for pharmaceutical and food processing requiring flex fatigue and biocompatibility
  • Inflatable packer bladders for oil well completion using heat-resistant grades
  • Marine and marine electrical cable jacketing requiring long-term salt water and UV resistance
  • Orthotic and prosthetic socket liners requiring cushioning and skin compatibility
  • High-purity semiconductor process tubing requiring low extractables and ozone resistance

Key Industries

Mobility

Healthcare

Building & Construction (sealing profiles, expansion joints)

Electrical & Electronics

Industrial

Consumer

Design, Assembly, and Aesthetics

  • Surface finish capability: TPV produces smooth matte surfaces suitable for sealing and functional applications. High-gloss surfaces require careful mold polishing and process optimization due to the rubbery nature of the material. Textured surfaces reproduce well across the hardness range. Weatherstrip and extrusion profiles produce consistent cross-sections with smooth surfaces. Medical grades produce surfaces compatible with clean room handling and sterilization processes.
  • Sink, warpage, and visible defect tendency: High shrinkage (1.5-3.0%) creates significant sink mark and warpage risk, particularly in thick sections. Uniform wall thickness is critical for dimensional control. Soft grades are prone to deformation during ejection and require careful demolding strategy including lower mold temperatures and extended cooling times. Overmolded parts require substrate pre-heating for adequate interfacial adhesion.
  • Colorability: TPV accepts a wide range of colorants including opaque, fluorescent, and transparent formulations. Carbon black grades provide outstanding UV stability for dark-colored outdoor parts. UV-stabilized grades without carbon black support light and vibrant colors for outdoor applications. Medical grades use controlled colorant systems meeting biocompatibility requirements. Color matching is consistent between production runs.
  • Color stability: Carbon black-filled grades maintain color indefinitely under UV exposure. UV-stabilized grades without carbon black maintain light colors for extended outdoor service with minimal Delta E shift. Heat exposure during processing within the recommended 190-230°C window does not cause visible color degradation. Avoid processing above 240°C to prevent PP matrix degradation and discoloration in finished parts.
  • Scratch and mar resistance: TPV surface hardness follows the Shore A or D scale of the specific grade. Soft grades show lower scratch resistance than harder formulations. The rubber-like surface recovers from minor deformation. Chemical mar from hydrocarbons and aromatic solvents is the primary concern in service. Standard cleaning with water, mild detergents, and isopropyl alcohol maintains surface appearance without damage.
  • Marking methods: Pad printing and screen printing accept standard flexible inks with minimal surface treatment. Laser marking applies to certain grades with laser-receptive additives. Hot stamping delivers decorative finishes on smooth surfaces. In-mold labeling integrates graphics during production. Embossed and debossed mold marks provide permanent identification. Test marking methods on specific grades, as results vary with hardness and formulation.
  • Coating and bonding suitability: TPV accepts flexible coatings and paints with appropriate primer systems. Corona or flame treatment improves adhesion for printing and bonding applications. Overmolding and co-extrusion onto PP substrates provide the strongest bonding method without adhesives. Flexible polyurethane or rubber-based adhesives support assembly with non-PP substrates. Solvent bonding is not recommended due to the risk of swelling soft grades.
  • Joining methods: Overmolding and co-extrusion with PP substrates provide the strongest joining method for TPV. Heat welding, vibration welding, and hot gas welding produce adequate bonds for same-material joining. Adhesive bonding using flexible polyurethane or rubber-based adhesives accommodates material compliance in non-PP assemblies. Press-fit designs work well for creating liquid-tight seals around rigid inserts. Mechanical fastening in soft grades requires careful design due to material compliance around fasteners.
IV drip hanging beside a hospital bed

Practical and Commercial Considerations

Processing equipment fit

TPV processes on standard reciprocating screw injection molding and extrusion equipment. Screw designs optimized for TPE materials (low compression ratio of 2:1 to 2.5:1, L/D ratio of 18:1 to 24:1) are preferred. General-purpose screws work adequately for harder grades above Shore 60A. Soft grades benefit from screws designed for elastomeric materials to minimize shear heating. Low back pressure during molding prevents frictional overheating. Vented barrels help with moisture. Profile extrusion for weatherstrip uses TPE-optimized dies with downstream cooling and sizing equipment.

Cycle time and productivity notes

Cooling time is the primary variable in TPV injection molding cycles. Soft grades require longer cooling to develop sufficient stiffness for ejection, with typical cooling times of 20-45 seconds for 2-3 mm wall thickness. Mold temperatures of 20-40°C work for most grades. Higher mold temperatures (40-60°C) improve surface finish for visible applications. TPV cycle times are competitive with thermoset rubber vulcanization, which requires 2-5 minutes for equivalent profile cross-sections, making TPV a significant productivity improvement for seal and weatherstrip manufacturing.

Drying requirements

Pre-dry TPV granules at 80°C for 2-3 hours in a desiccant or hot air dryer to achieve moisture content below 0.1%. TPV absorbs less moisture than nylon or TPU but requires drying for optimal surface quality and consistent processing. Insufficient drying causes surface bubbles and splay marks in molded parts. Sealed packaging should remain closed until loaded into the dryer. Hopper dryers maintain dry conditions during extended production runs.

Melt and mold temperature guidance

Process TPV at melt temperatures of 190-230°C. Softer grades (Shore 35-60A) process at the lower end (190-210°C) to minimize shear heating. Harder grades (Shore 80A to 50D) process at 210-230°C. Avoid melt temperatures above 240°C to prevent PP matrix degradation and color shift. Mold temperatures of 20-40°C work for most injection molding applications. Higher mold temperatures (40-60°C) improve surface finish for visible exterior or consumer parts. Extrusion barrel temperatures follow similar profiles, with die temperatures at the lower end of the melt range for optimal surface quality.

Shrinkage

Mold shrinkage of 1.5-3.0% is significantly higher than rigid thermoplastics and varies with hardness, wall thickness, packing pressure, and cooling rate. Soft grades show the highest shrinkage (2.5-3.0%). Harder grades shrink less (1.5-2.0%). Post-mold shrinkage continues for 24-48 hours as the PP matrix crystallizes. Account for this post-mold change in dimensional verification. Extrusion profiles require careful calibration of die dimensions to compensate for draw-down and shrinkage during cooling.

Dimensional stability and tolerance capability

Very low moisture absorption (0.1-0.3%) produces minimal dimensional change in service. High shrinkage and material compliance limit achievable tolerances. Standard injection-molded parts achieve tolerances of ±0.3-0.5 mm for soft grades and ±0.2-0.3 mm for harder grades. Precision sealing profiles achieve cross-sectional tolerances within ±0.1 mm for harder formulations. Thermal expansion of 130-200 x 10-6 /°C is high relative to rigid thermoplastics and must be accounted for in assemblies subject to temperature cycling.

Regrind and scrap utilization

TPV accepts regrind at 10-25% ratios without significant property loss for most industrial applications. Clean, single-source regrind from runners and sprues maintains properties close to virgin resin. Medical and food contact applications prohibit regrind use. Automotive weatherstrip applications limit regrind to 10-15% to maintain compression set performance. Dry regrind with virgin material before processing. Multiple reprocessing cycles degrade compression set performance progressively. Granulate and dry in-process scrap promptly to minimize moisture pickup.

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Frequently Asked Questions

What is dynamic vulcanization and why does it matter for TPV performance?

Dynamic vulcanization is the manufacturing process that makes TPV fundamentally different from other thermoplastic elastomers. During production, EPDM rubber and polypropylene are melt-blended in a twin-screw extruder while a curing agent crosslinks the rubber phase simultaneously. The result is fully crosslinked EPDM rubber particles averaging 1-5 micrometers in diameter, uniformly dispersed throughout a continuous PP matrix.

The crosslinked rubber particles deliver elastic recovery, compression set resistance, and high-temperature stability. Non-vulcanized TPE blends (such as SEBS compounds) show significantly higher compression set and poorer heat resistance because their rubber phase lacks this crosslinked structure. Dynamic vulcanization is what allows TPV to approach the sealing performance of thermoset rubber while remaining fully processable on standard thermoplastic equipment.

How does TPV compare to thermoset EPDM rubber?

TPV delivers mechanical and sealing performance approaching thermoset EPDM vulcanizate, with significant processing and sustainability advantages. Thermoset EPDM requires mold curing at 150-200°C for 2-10 minutes per cycle, generates scrap impossible to recycle, and demands vulcanizing compounds and specialized equipment. TPV processes by injection molding or extrusion in seconds to minutes and generates fully recyclable scrap.

TPV advantages over thermoset EPDM: faster processing cycles, recyclability, lower system cost, cleaner manufacturing, and direct adhesion to PP in co-extrusion. Thermoset EPDM advantages: lower compression set in the best formulations (10-20% vs. 25-50% for TPV at 70°C) and higher chemical resistance to hydrocarbons. For most automotive weatherstripping, construction sealing, and appliance gasket applications, TPV delivers adequate performance with compelling processing and recyclability benefits.

What are the compression set limitations of TPV and when do they matter?

Compression set measures how much a material permanently deforms after sustained compression. Standard Santoprene grades deliver 25-50% compression set (22 hours at 70°C, ASTM D395 Method B), substantially better than non-vulcanized SEBS TPE (typically 50-80%) but higher than thermoset EPDM (10-20%). For most automotive weatherstripping, appliance gaskets, and construction seals operating below 100°C, TPV compression set performance meets the expected service life.

Applications with extreme sealing requirements, sustained high temperatures above 100°C, or very long service intervals should validate compression set for the specific grade and application conditions. Celanese offers specialty low-compression-set Santoprene grades for the most demanding static sealing specifications. Work with Formerra's technical team to identify the right grade before finalizing material selection for critical sealing applications.

Does TPV require special processing equipment?

No special equipment is required. TPV processes on standard injection molding, extrusion, and blow molding equipment. Key processing considerations include screw design (lower compression ratio of 2:1 to 2.5:1 preferred for soft grades), melt temperature control (190-230°C, do not exceed 240°C), and pre-drying at 80°C for 2-3 hours before processing.

The main difference from rigid thermoplastics is demolding strategy for soft grades. Low mold temperatures (20-40°C), smooth mold surfaces, and generous draft angles reduce demolding forces. Extrusion lines for weatherstrip and profile production use standard TPE-compatible dies and downstream cooling equipment. No post-cure steps, vulcanization equipment, or specialized rubber processing machinery are needed, which makes converting from thermoset rubber to TPV a straightforward equipment transition.

What are the key differences between TPV, SEBS-based TPE, and silicone for flexible applications?

TPV offers better compression set resistance than SEBS TPE (25-50% vs. 50-80% at 70°C), better upper temperature performance (135°C vs. 90-100°C), and better UV and ozone resistance than polybutadiene-based TPE compounds. TPV is typically less expensive than SEBS-based compounds for comparable hardness grades. Choose TPV when sealing performance, heat resistance, and ozone resistance drive the design.

SEBS-based TPE offers better optical clarity for transparent applications, lower density, and easier processing for very soft grades. It is adequate for lower-temperature applications not requiring compression set performance. Silicone offers the widest temperature range (-60°C to 200°C and above), the lowest compression set of any elastomer, and the best biocompatibility for implantable medical devices. Silicone costs 3-6 times more than TPV per kilogram and requires specialized LSR injection molding equipment. Choose TPV when thermoset rubber performance is required at thermoplastic processing efficiency.

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Sources

Santoprene Thermoplastic Vulcanizate Processing Guide. Celanese. 2024. 

Santoprene TPV Technical Data Sheets and Application Guides. Celanese. 2024.

Thermoplastic Elastomers: Rubber-Plastic Blends. Hanser Publications. 2022.

Dynamic Vulcanization in Thermoplastic Elastomers. Society of Plastics Engineers Technical Paper. 2022.

Santoprene Medical Grade Product Guide. Celanese. 2023.