Prior to the advent of TPEs, soft PVC compounds or rubbers were utilized in applications requiring flexibility, elasticity, and softness. However, with the development of various TPEs, this new family quickly replaced PVC or elastomer-based compUnderstanding the material advantages of PVC vs TPE for flexible parts is essential when selecting the optimal polymer for soft component manufacturing. Before the emergence of thermoplastic elastomers (TPEs), soft PVC compounds and rubber materials were commonly used in products that required flexibility, elasticity, and softness. However, with the advancement of various TPE families, these new materials rapidly replaced PVC and elastomer-based alternatives in numerous industries. This article offers a side-by-side, qualitative comparison between PVC and TPE for manufacturing soft parts such as caps, plugs, seals, and gaskets.
PVC: Affordable and Accessible Material for Flexible Applications
Polyvinyl chloride (PVC) is widely known for its availability and low cost. To be suitable for manufacturing flexible parts, PVC requires several additives—such as stabilizers, plasticizers, lubricants, impact modifiers, and fillers—to modify its behavior. Its applications span industries including window gaskets, footwear soles, cable insulation, and consumer packaging.
Some of the major advantages of PVC include:
- High mechanical strength
- Good UV resistance (sunlight exposure)
- Strong abrasion resistance
- Flame retardant behavior
- Low electrical conductivity
However, PVC is not without limitations. Its drawbacks include:
- Low thermal resistance
- Higher weight and density
- Toxic gas emissions during melting or degradation
TPE: Advanced Polymer Family for High-Performance Flexible Parts
On the other hand, TPEs (Thermoplastic Elastomers) offer a modern solution for flexible manufacturing. They can function at elevated temperatures (up to ~170 °C) and are capable of exhibiting unique surface properties and enhanced performance under stress. Unlike PVC, TPEs are environmentally friendly and do not emit harmful gases throughout their lifecycle.
Key advantages of TPEs are:
- Exceptional flexibility and softness
- High fatigue and impact resistance
- Superior chemical resistance
- Low density, making products lighter
- Excellent processability using conventional thermoplastic equipment
- Suitable for advanced applications (e.g., medical devices, automotive interiors)
That said, TPE materials also come with challenges, primarily:
- Higher raw material costs
- Dimensional instability during long-term use (aging, thermal resistance drop, and creep under load)
Choosing Between PVC vs TPE for Flexible Parts
The choice between PVC and TPE for flexible part production should be based on the specific technical and commercial requirements of the application. PVC remains an economical choice for general-purpose parts, whereas TPEs offer superior performance, especially when heat resistance, chemical durability, and environmental compliance are priorities.
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Next: Side-by-Side Technical Comparison of PVC vs TPE Properties
The following tables provide a detailed comparison of mechanical, physical, and chemical resistance properties of PVC and various TPE grades to assist in material selection and performance evaluation.
| PVC | TPE | |
| Tensile Strength | 2.60 N/mm² | 0.5 – 2.4 N/mm² |
| Notched Impact Strength | 2.0 – 45.0 Kj/m² | No break Kj/m² |
| Thermal Coefficient of expansion | 80 x 10-6 | 130 x 10-6 |
| Max Cont Use Temp | 60˚C / 140˚F | 140˚C / 284˚F |
| Density | 1.38g/cm3 | 0.91 – 1.3 g/cm3 |
| PVC | TPE | |
| Dilute Acid | Very good | Excellent |
| Dilute Alkalis | Very good | Excellent |
| Oils and Greases | Good (variable) | Excellent |
| Aliphatic Hydrocarbons | Very good | Excellent |
| Aromatic Hydrocarbons | Poor | Poor |
| Hydrogenated Hydrocarbons | Moderate (variable) | Poor |
| Alcohols | Good (variable) | Excellent |