TPR vs. PVC: Material Differences and Comparisons

Thermoplastic Rubber (TPR) is a synthetic elastomer that combines the processing advantages of plastics with the elasticity of rubber. It can be repeatedly melted and reformed, making it ideal for injection molding and extrusion. TPR is commonly used in applications requiring flexibility, durability, and slip resistance, such as shoe soles, grips, soft-touch handles, and seals. 

Polyvinyl Chloride (PVC) is a widely used engineering thermoplastic known for its chemical resistance and versatility. It is available in two forms: rigid (uPVC) and flexible (plasticized PVC). Rigid PVC is extensively used in the construction industry for pipes, profiles, and fittings, while flexible PVC is found in protective equipment, flexible tubing, and insulation. Both types can be processed using extrusion, injection molding, or blow molding.

This article compares TPR and PVC in terms of properties, processing methods, applications, and cost considerations to help guide material selection based on performance and end-use requirements.

What Is TPR?

TPR refers to a class of synthetic elastomers that can be melt-processed using conventional thermoplastic manufacturing methods such as injection molding, compression molding, and blow molding. These materials exhibit rubber-like elasticity at room temperature but soften and flow when heated, allowing for efficient shaping and reshaping without permanent chemical changes. In contrast, traditional rubbers, both natural and synthetic (e.g., butyl rubber), are typically thermoset materials. They do not melt upon heating and will undergo thermal degradation if overheated due to their cross-linked molecular structure. TPR is used in applications that demand a flexible, durable, and high-grip material, especially when the part geometry is complex and requires processing through thermoplastic techniques. It offers a balance of properties, including good toughness, chemical resistance, and fatigue resistance, making it suitable for grips, seals, soft-touch components, and overmolded parts.

For more information, see our guide on Thermoplastic Rubber.

TPR is made up of Styrene Butadiene-Styrene (SBS), which is a type of block copolymer. TPR is synthesized using a process called living anionic polymerization. This is a chain polymerization process that polymerizes two monomers, namely butadiene and styrene, into SBS. This creates a polymer structure with hard, crystalline regions and soft, amorphous regions. The hard regions contain styrene, and the soft regions contain butadiene. The hard regions provide the thermoplastic properties, whereas the amorphous regions supply the elastomeric properties.

What Is PVC?

PVC is an engineering thermoplastic with excellent resistance to moisture ingress and UV (ultraviolet light). Its good abrasion resistance makes it a popular choice for piping and construction materials. PVC is generally available in two forms, namely plasticized (PVC-P) and unplasticized (PVC-U). Unplasticized PVC is used in parts that require rigidity, like pipes and fittings. Plasticized PVC is used in applications that require flexibility, like cables, tubes, and PPE (personal protective equipment). Modified grades of PVC are available, which have various additives to improve PVC properties,  such as overall strength. These grades are referred to as PVC-M (Modified). PVC can be melt-processed using injection molding, extrusion, and blow molding. Additionally, PVC pipes and fittings can be bonded with glue. 

Figure 1 is an example of PVC pipes:

TPR vs. PVC: Applications and Uses

TPR has been widely used for shoe soles due to its slip resistance, low cost, and flexibility. Some typical applications are listed below:

1. Shoe soles
2. Dog toys
3. Tire treads
4. Gaskets

PVC is available in both rigid and flexible forms. The applications listed below relate to the flexible form of PVC for comparative purposes. PVC has excellent chemical resistance.

1. Cables
2. Tank liners for chrome plating
3. PVC films
4. Flooring, roofing
5. Flexible pipe and hose
6. Waterproofing membranes
7. Packaging

TPR vs. PVC: Physical Properties

Table 1 below lists the mechanical, thermal, and electrical properties of TPR as well as those of rigid and flexible PVC:

TPR represents a wide range of different formulations. As such, the values represented in Table 1 only serve as a snapshot of the potential range of properties. Always consult a raw material supplier for more applicable datasheets when choosing a material.

TPR vs. PVC: Recyclability and Sustainability

PVC and TPR are both produced from crude oil, which is non-renewable and a pollutant; therefore, they cannot be regarded as sustainable. PVC can be recycled up to eight times. Despite this recyclability, the vast majority of plastics are not recycled; they simply end up in landfill sites or in the ocean.

TPR is a thermoplastic and, as such, can be theoretically recycled. However, plastic recycling is already quite rare, with far more popular commodity plastics like polyethylene being less frequently recycled. In light of this, recycling lower-volume materials, like TPR, is not typically economical or common practice.

TPR vs. PVC: Cost

TPR is generally more expensive than PVC, primarily due to its elastomeric properties and more complex formulation. TPR combines the flexibility of rubber with the processing advantages of thermoplastics, which increases production costs. 

In contrast, PVC is produced on a much larger global scale, approximately 44.3 million metric tons annually, which significantly lowers its cost. PVC is one of the most economical engineering thermoplastics available. Pricing for PVC can reach up to USD $1,389 per metric ton, while TPR generally falls in the range of USD $1,470 to $2,250 per metric ton. Actual prices vary depending on formulation, market demand, and processing requirements.

Alternative Materials to TPR and PVC

A suitable alternative to TPR or flexible PVC would be either TPE-S (also known as the thermoplastic elastomer SEBS) or TPU (thermoplastic polyurethane). These materials have similar elastomeric properties, as well as comparable mechanical properties, like tensile strength and elongation. Potential replacements for rigid PVC include polypropylene or HDPE (High-Density Polyethylene). Both of these materials have excellent corrosion resistance and toughness.

Summary

This article presented TPR and PVC, explained each of them, and discussed their various differences. To learn more about TPR and PVC, contact a Xometry representative.

Xometry provides a wide range of manufacturing capabilities and other value-added services for all of your prototyping and production needs. Visit our website to learn more or to request a free, no-obligation quote.

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