In material selection for moulded components, the difference between a part that performs and one that falls short often comes down to choosing the right polymer. At PRP Polymer Engineering, we help customers understand how materials behave not just theoretically, but in different environments.
With over 50 years of experience in precision injection moulding, tooling design and automated production, we support our customers in selecting the most suitable material for their performance, cost and sustainability goals. One of the most common areas of confusion is the distinction between Thermoset Rubber (TSR), Thermoplastic Elastomers (TPE/TPR) and Thermoplastic Vulcanizates (TPV).
Understanding the Materials
TSR, TPE and TPV may all be used to create flexible, rubber-like components, but they behave very differently during moulding and throughout their service life.
- Rubber (TSR)
- TPR / TPE (Thermoplastic Rubber / Thermoplastic Elastomer)
- TPV (Thermoplastic Vulcanizate)
TSR undergoes a vulcanisation process, where the material is heated to create new cross-linked polymer structures. This irreversible change delivers excellent resistance to high temperatures, hot oils and fuels, and provides robust mechanical strength. However, it also limits recyclability and results in longer production cycle times.
TPE and TPV, on the other hand, follow the standard thermoplastic injection moulding process — plasticising and heating material granules before injecting them into a cooled tool. Unlike TSR, this process does not change the polymer structure, meaning TPE and TPV can be remelted, reprocessed and fully recycled. They provide the tactile feel and flexibility of rubber combined with the production efficiency of a thermoplastic — a major advantage for high-volume applications.
Comparative Performance
Some TSR grades provide exceptionally high mechanical performance, particularly where components must withstand elevated temperatures, oils, fuels or continuous mechanical stress. In these demanding environments, TPE and TPV may not be suitable.
However, when compared with materials such as Natural Rubber, EPDM and Polychloroprene in more typical applications, TPE and TPV can offer a comparable level of performance, with additional advantages in:
- Production costs
- Recyclability
- Weight reduction
- UV resistance
- Availability of independently certified grades (e.g. UL94 flammability standards)
TPE and TPV can be recycled through conventional routes. TSR can be recycled, but only in large quantities, and future uses are limited because the material’s structure was permanently changed during vulcanisation.
Choosing the Right Material
Selecting the most suitable material for an application begins with understanding the full set of requirements. The more detail available early in the process, the more accurate the material match.
Key considerations include:
- Operating temperature range
- Chemical exposure (oils, fuels, cleaning agents, etc.)
- UV and weathering conditions
- Requirements for sealing performance
- Flammability standards that must be met
- Impact on tooling costs and available moulding options
We can supply manufacturer-issued data sheets to help compare materials directly and provide guidance on suitability, expected performance, and the implications each choice may have on tooling costs and design options.
Partnering for Success
At PRP, we believe in long-term, collaborative partnerships. Our experienced engineers work closely with you throughout the design and manufacturing process — offering insights, problem-solving support and practical recommendations to ensure the selected material meets the demands of your product.
We operate rigorous quality control procedures throughout production, ensuring every component delivers reliability, consistency and long-term performance.
Let’s Build Something Great Together
Your product deserves the right balance of performance, durability, and cost-efficiency. With PRP Polymer Engineering, you gain a partner who brings deep material knowledge, advanced manufacturing capabilities, and decades of experience.
Ready to take the next step? Contact us today to discuss your material requirements and discover how the right choice can elevate the performance of your product.
