Among the most advanced materials used in injection moulding departments is TPU, a thermoplastic polyurethane with elastomeric behaviour that combines the processability of thermoplastics with the flexibility and elasticity typical of elastomers.

Thanks to these characteristics, TPU (thermoplastic polyurethane) represents a versatile, durable and high-performance solution, suitable for numerous industrial sectors, ranging from automotive to industrial design, and offers a more sustainable alternative to traditional rubber materials.

In this article, we analyse what TPU is, its main properties, its advantages compared with other materials, and its most common applications in industrial moulding.

What is TPU?

Thermoplastic polyurethane (TPU) is a high-performance polymeric material belonging to the family of thermoplastic elastomers (TPE).

Its outstanding performance derives from a segmented molecular structure composed of soft domains and hard domains. This configuration gives the material a unique balance of flexibility, mechanical strength, abrasion resistance, stability and processability, distinguishing it from other TPE materials and making it suitable even for complex industrial processes.

The soft domains are responsible for the elastomeric behaviour of the material, ensuring high elasticity, excellent shock absorption, and effective shape recovery even after significant deformation.

The hard domains, on the other hand, provide TPU with the typical properties of thermoplastics, ensuring mechanical strength and dimensional stability. They act as reversible physical bonds that temporarily disorganise when heat is applied.

Although TPU exhibits elastomeric behaviour, it is not a traditional rubber. Thanks to the reversible bonds of the hard domains, it can be melted, shaped and processed using common industrial manufacturing methods, such as injection moulding.

When heated, the material softens and can be processed with high precision. During cooling, it retains the given shape without losing its mechanical, chemical or dimensional properties.
This reversibility allows the material to be recovered and reused several times, offering significant advantages in terms of recyclability, waste reduction and production cost optimisation compared with traditional elastomers.

Main properties of TPU

The structural characteristics of thermoplastic polyurethane, resulting from the alternation of soft and hard domains, translate into a range of mechanical, chemical and functional properties that define its wide range of industrial applications.

Elasticity and mechanical strength

TPU is characterised by high elasticity, with elongation at break reaching up to 600%, while maintaining excellent elastic recovery even under repeated deformation.
It also shows good fatigue resistance, retaining its mechanical properties under cyclic loads and continuous stress.
Tensile strength, typically between 30 and 50 MPa, is higher than that of many industrial rubbers, ensuring durability, reliability and dimensional stability even under mechanical stress. The material also effectively absorbs shocks and vibrations.

Wear and abrasion resistance

Under demanding operating conditions, TPU can be up to ten times more abrasion-resistant than natural rubber. This makes it particularly suitable for components subject to constant friction, ensuring a long service life without deformation.

Chemical stability

TPU tolerates contact with oils, greases, fuels and solvents, maintaining mechanical integrity and functional performance even in aggressive industrial environments.

Thermal stability

Thermoplastic polyurethane maintains consistent performance over a temperature range of approximately –40 °C to +120 °C; special TPU formulations can withstand peak temperatures of up to 150 °C.
Even at low temperatures, TPU retains flexibility and impact resistance, avoiding the stiffening or brittleness typical of other thermoplastic elastomers.

Adjustable hardness

By varying the chemical composition, TPU can achieve hardness levels ranging from Shore A 60 to Shore D 80, making it suitable for both flexible components and parts with a more structural function.

Processability and recyclability

As a thermoplastic material, TPU does not require vulcanisation processes and can be processed by injection moulding. It is also remeltable and reusable, contributing to waste reduction and improved sustainability of manufacturing processes.

UV and weather resistance

Certain TPU grades offer good resistance to UV radiation and weathering, maintaining mechanical and aesthetic stability over time. This allows the material to be used in outdoor applications, reducing degradation, discolouration and performance loss.

Finish and design

The natural transparency of TPU allows for neutral or coloured finishes, combining high technical performance with aesthetic and functional requirements. 

TPU applications across different industrial sectors

The ability to modulate composition and additives in TPU formulations makes it possible to obtain materials with specific characteristics tailored to different application requirements. This design flexibility supports its widespread use in modern industrial moulding across numerous sectors.

Below are some of the main TPU applications that can be designed and developed on a custom basis.

Furniture

In the furniture sector, TPU is valued for its combination of flexibility, impact resistance and aesthetic quality, enabling the production of durable and functional components such as:

• balancing elements for orthopaedic slatted bed bases
• anti-impact furniture feet
• seat inserts
• decorative profiles
• joint seals
• coatings for design components with neutral or coloured finishes

Textile

In the textile industry, TPU is ideal for elastic and durable solutions suitable for intensive cycles and repeated stress, including:

• flexible eyelets
• cord ends
• belt loops
• soft supports
• anti-slip inserts for technical clothing
• solutions for industrial textile applications

Lighting

Thanks to its insulating properties and thermal stability, TPU is used in lighting components exposed to heat and electrical stress, such as:

• electrical insulators
• lamp suspension hooks
• spotlight supports
• heat- and discharge-resistant covers

Manufacturing

In industrial manufacturing, TPU is a reliable solution for components subject to wear, vibration and mechanical stress, including:

• industrial seals
• caps and closures
• sealing rings
• anti-vibration dampers
• elements for assembly lines
• components for olive harvesting systems
• protective coatings for machinery

Hydraulic systems

Resistance to water, oils and chemicals makes TPU particularly suitable for hydraulic components, including:

• flexible hoses
• sealing gaskets
• fluid movement spools
• valves and connection devices

Marine and boating

In the marine sector, TPU is used for elastic and protective components exposed to water, UV radiation and impacts, such as:

• boat fenders
• anti-impact end pieces
• coatings for metal supports
• overmoulded nautical equipment
• protection for external components

Automotive

In the automotive industry, TPU is used for technical components requiring strength, flexibility and long-term stability, such as:

• dashboard cable grommets
• anti-vibration supports
• fuel hoses
• technical coatings for electrical systems
• protection for electric vehicle batteries

Railway

In the railway sector, TPU is selected for components subject to constant mechanical stress and high safety requirements, including:

• carriage dampers
• wheels for sliding systems
• elastic infrastructure supports