TPE Vs TPR Key Differences in Thermoplastic Elastomers
January 27, 2026
Selecting the ideal material for product design can be challenging, especially when faced with the wide array of elastomer options available. Thermoplastic elastomers (TPE) and thermoplastic rubbers (TPR) often present a dilemma due to their similar appearances and comparable properties. However, subtle differences between these materials can significantly impact product performance. This article provides an in-depth analysis of TPE and TPR characteristics, applications, and selection criteria to help you make informed decisions.
At first glance, TPE and TPR share many common properties:
- High flexural fatigue resistance
- Excellent tear and abrasion resistance
- High impact strength
- Good dielectric properties
- Superior weather and chemical resistance
- Recyclability
- Operating temperature range: -30°C to 140°C
The fundamental difference between these materials lies in their base polymers. TPE is typically modified from SEBS (styrene-ethylene-butylene-styrene block copolymer), while TPR is commonly modified from SBS (styrene-butadiene-styrene block copolymer).
SEBS is the hydrogenated version of SBS. SBS, a styrene-butadiene-styrene block copolymer, is widely used in hand tools and other products requiring soft touch surfaces. Hydrogenation introduces molecular hydrogen into unsaturated molecules under specific reaction conditions, resulting in saturated molecular structures that enhance anti-aging and anti-yellowing properties. This process also improves heat and corrosion resistance, making TPE generally superior to TPR in performance.
- Polyolefin blends (TPE-O)
- Styrenic block copolymers (TPE-S)
- Elastomer alloys
- Thermoplastic polyurethanes (TPE-U)
- Thermoplastic polyamides (TPE-A)
- Thermoplastic copolyesters (TPE-E)
Both TPE and TPR combine the moldability of plastics with the elasticity of rubber, making them valuable in engineering applications. Material hardness is measured using the Shore durometer scale. TPE can be formulated into soft gel materials ranging from 20 Shore OO to 90 Shore AA. Beyond 90 Shore AA, materials transition to the Shore D scale, reaching up to 85 Shore D.
TPR offers a similarly broad hardness range from 20 Shore OO to 85 Shore D. In solid state, TPE is a multiphase material consisting of soft and hard domains. Its rubber-like properties derive from the glass transition temperature of the rubber phase and the melting or glass transition temperature of the hard phase.
- Excellent weather resistance
- Good high-temperature resistance
- Superior fatigue resistance
- Cost reduction potential
Common applications include medical devices, hardware tools, electronic appliances, sports equipment, toys, automotive components, and communication devices.
TPR is a thermoplastic soft rubber material combining the physical properties of rubber with the injection molding capabilities of thermoplastics. Typical applications include custom automotive floor mats and truck bed liners.
Key characteristics of TPR include:
- Good shape retention
- Adjustable flexibility
- Increased flexibility with higher rubber content
- Controllable odor
- Lightweight
- Customizable colors
TPR performs better than TPE in bonding applications (e.g., footwear and toys) as TPE doesn't respond well to adhesives. Other TPR applications include:
- Pipes
- Wires and cables
- Sealants
- Asphalt modifiers
- Automotive trim
- Gaskets
- Packaging
- Films and sheets
- Injection molded parts
| Property | TPE | TPR |
|---|---|---|
| Base Material | SEBS modified | SBS modified |
| Surface Appearance | Matte with slight diffusion | Reflective glossy surface |
| Tactile Feel | Smooth and comfortable | Slightly tacky |
| Combustion Smoke | Lighter | Darker and thicker |
| Primary Applications | Food, healthcare, seals, bottle caps and liners | Products requiring bonding, glossy surfaces, or coloring |
| Advantages | Weather resistance, high-temperature resistance, fatigue resistance, cost-effective | Chemical resistance, easy processing, colorability |
| Disadvantages | Relatively higher cost | Lower tensile strength, aging resistance, and mechanical properties |
| Material | TPE | TPR |
|---|---|---|
| Dilute Acids | Excellent | Excellent |
| Dilute Bases | Excellent | Excellent |
| Oils | Excellent | Excellent |
| Aliphatic Hydrocarbons | Excellent | Excellent |
| Aromatic Hydrocarbons | Moderate | Good |
| Halogenated Hydrocarbons | Moderate | Moderate |
| Alcohols | Excellent | Good |
TPE can significantly reduce costs as it can be processed on standard plastic machinery. It combines the aesthetic appeal of traditional thermoplastic rubber with easy processing, making it suitable for high-volume injection molding. Both TPE and TPR are 100% recyclable and can typically be reused up to five times (depending on grade).
TPR offers the appearance, feel, and elasticity of thermoset rubber combined with the processability of plastics. It's suitable for injection molding, blow molding, and thermoforming processes. While rubber materials are generally considered to have higher tensile strength, material selection should be based on specific project requirements and component characteristics.
In essence, TPE can be considered a softer version of TPR, making it the preferred choice when greater flexibility and softness are required.