TPE (thermoplastic elastomer) is the umbrella term for polymers that stretch and recover like rubber but melt and process like thermoplastics. ISO 18064 groups them into families such as styrenic (TPS), polyurethane (TPU), copolyester (TPC) and vulcanizate (TPV) elastomers. Filaments sold as TPE for FDM are usually soft styrenic compounds or soft TPU grades in the Shore 60A to 90A range, noticeably softer and more elastic than TPU 95A.
Choose TPE for parts that must feel soft or grip: handles and overlays, feet and anti-slip pads, vibration dampers, soft covers, gripper fingers and prototypes of overmolded parts. Its limits are clear: the softest grades are slow and demanding to print, heat resistance is modest, compression set is higher than with silicone, and properties vary strongly between grades. TPE filament is offered through Uretyco's partner network; for very soft grades, printability and lead time are confirmed during quote review.
Mechanical and physical properties
| Property | Typical value | Notes |
|---|---|---|
| Hardness | Shore 60–90A | Measured on solid material per ASTM D2240 or ISO 868. Grades below about 80A are harder to print and less widely available. |
| Tensile strength | ≈ 5–35 MPa | Very grade-dependent: soft styrenic grades sit at the low end, soft TPU grades at the high end. Printed parts reach less. |
| Elongation at break | ≈ 300–700% | Filament datasheet values; printed parts stretch less, especially across layers. |
| Tear resistance | Lower than TPU 95A | Softer grades tear more easily from notches, sharp corners and layer seams. |
| Compression set | Moderate to high | Higher than silicone and rising with temperature; tested to ISO 815-1 or ASTM D395. |
| Density | ≈ 0.9–1.2 g/cm³ | Styrenic compounds are lighter; TPU-based grades ≈ 1.1–1.2 g/cm³. |
| Service temperature | ≈ −30 to +70 °C | Grade-dependent; soft parts lose stiffness well before the upper limit. |
| Chemical resistance | Grade-dependent | TPU-based grades resist oils and greases; styrenic TPE resists water, dilute acids and alkalis but swells in oils, fuels and many solvents. |
| UV and weathering | Grade-dependent | Hydrogenated styrenic (SEBS) grades weather well; aromatic TPU yellows in sunlight. Check the datasheet for outdoor parts. |
| Moisture sensitivity | Low to high | TPU-based filaments absorb moisture and must be dried before printing; styrenic grades absorb very little. |
Typical ranges from filament datasheets for soft TPE and TPU grades. The class is broad, so values differ widely between chemistries and brands, and printed parts depend on infill, wall count, orientation and layer bonding. Use the datasheet of the grade named in your quote and test printed samples under the real load and temperature.
Printing TPE with FDM
Soft filament tends to compress and buckle in the extruder instead of feeding cleanly. It needs a direct-drive extruder with a tightly constrained filament path, slow and steady print speeds and little retraction, so not every printer can run the softest grades. Design and ordering points:
- Hardness and printability: grades around 85–90A print reliably; 60–80A grades print slower and limit the geometry. If the exact hardness is not critical, state whether a firmer grade is acceptable.
- Walls and small features: use at least two to three perimeters and avoid walls thinner than about 1 mm; small pins, fine ribs and text blur or tear.
- Overhangs and supports: keep overhangs within about 45° of vertical and avoid long bridges. Supports bond firmly to soft material and tear the surface when removed, so give the part a flat face on the build plate.
- Softness through geometry: infill density, infill pattern and wall count set how soft the part feels. A part with low infill feels much softer than the material's Shore value, so state whether parts should be solid.
- Orientation: tears start at layer seams. Orient straps, lips and hinges so they stretch and bend along the layers, not across them.
- Fits: soft parts can hold by interference, for example as push-on fits over pins or hose barbs. Test a sample before ordering a batch.
Tolerances and surface
Without a drawing tolerance, Uretyco applies the FDM default of ±0.5 mm or ±0.5%, whichever is greater; actual results vary with material shrinkage, orientation, part size, supports and post-processing. Soft parts add a further complication because they deform under the measuring force. Define how critical dimensions are measured, and design fits with clearance or deliberate interference rather than tight nominal values. Surfaces are satin to matte with visible layer lines; very soft grades show more stringing and less crisp edges.
Finishing options
Soft TPE smears rather than sands, does not machine well, and rigid paints crack as soon as the part flexes. Color and surface quality therefore come mainly from the filament and the print itself.
| Finish | Effect | Notes for TPE |
|---|---|---|
| As-printed | Lowest cost | Layer lines and some stringing; small strings are trimmed by hand. |
| Manual cleanup | Clean edges and openings | Removal of strings, brims and support remnants; name the edges that must be clean. |
| Colored filament | Color without coating | Fewer colors than rigid filaments, especially for soft grades; confirm the color in the quote. |
| Flexible coating | Color or soft-touch feel | Only elastic coatings tolerate bending; adhesion is grade-dependent and must be tested. |
A firmer, easier-to-print grade combined with low infill, thin walls or a lattice often reaches the required feel more reliably than the softest filament. If the target is a feel rather than a measured Shore value, describe it so the quote can propose the most printable combination.
Cost and lead-time drivers
TPE filament costs more than PLA, but print time dominates the price of soft parts:
- Print speed: soft filaments print at a fraction of the speed of rigid ones, so part volume and wall count weigh heavily.
- Hardness: the softer the grade, the slower the print, the higher the risk of failed prints and the fewer printers that can run it.
- Supports and cleanup: removing supports from soft material is slow manual work; self-supporting geometry saves time and cost.
- Material preparation: TPU-based filaments must be dried before printing, which adds preparation time.
- Quantity: for tens of identical parts, cast polyurethane in silicone molds can become competitive; for production volumes, molding is the usual route.
TPE vs. other elastomers
| Material | Hardness | Temperature range | Compression set | Best for | Processes on Uretyco |
|---|---|---|---|---|---|
| TPE (FDM) | Shore 60–90A | ≈ −30 to +70 °C | Moderate to high | Soft prototypes, grips, dampers | FDM |
| TPU 95A | Shore 95A | ≈ −30 to +80 °C | Moderate | Tough, abrasion-resistant flexible parts | MJF, FDM, injection molding |
| Silicone (LSR) | Shore 10–80A | ≈ −50 to +200 °C | Low; very good for seals | Seals, gaskets, high temperatures | Injection molding, silicone molding |
| Cast polyurethane | Shore 30–95A (elastomer grades) | Similar to TPU | Moderate | Production-like soft parts in small batches | Casting, silicone molding |
Choose TPU 95A when abrasion, tear resistance and toughness matter more than softness. Silicone is the material for seals, heat and long-term compression. Cast polyurethane delivers small batches of soft parts with molded surfaces and a defined hardness, while TPE on FDM is the fastest way to test the feel and fit of a soft part.
When not to choose TPE
Static seals under long-term compression, especially when warm: use silicone. Service above about 60–70 °C. Contact with oils or fuels when the grade is styrenic: specify a TPU-based grade or choose another elastomer. Precise dimensions or a tightly toleranced Shore value: the softness of printed parts varies with infill and walls. Skin-contact, medical or food-contact parts: compliance depends on a certified grade, process validation and the customer's own regulatory responsibility, and FDM layer seams are hard to clean. Production volumes: casting or molding costs less per part.
Typical applications
- Soft grips, handle overlays and anti-slip pads.
- Feet, bumpers and vibration dampers for devices and fixtures.
- Soft gripper fingers and pads for handling delicate parts.
- Flexible covers, dust boots and bellows prototypes.
- Prototypes of overmolded and soft-touch parts before tooling.
- Low-pressure gaskets and seals for prototypes and test rigs.
Specifying TPE on Uretyco
- 1Upload STL, 3MF or STEP
Check units and scale; add a STEP file or drawing when fits or sealing faces matter.
- 2Select TPE and state the hardness
Give the target Shore value and how critical it is. For very soft grades, printability and availability are confirmed during quote review.
- 3Describe the use
Tell the AI assistant about compression, stretching, temperature, oils and skin contact; it can point to TPU 95A or silicone when TPE is marginal.
- 4Define infill, walls and orientation
State whether parts are solid or infilled, the wall count if it matters, and the faces that must be smooth or seal.
- 5Review the quote and test a sample
Check grade, hardness and lead time, and order a sample for feel and fit before a larger batch.
FAQ
Is TPE the same as TPU?
TPU is one family within the TPE class. Filaments labeled TPE are usually softer styrenic compounds or soft TPU grades. TPU-based grades offer better abrasion and oil resistance; styrenic grades are often softer and weather better but swell in oils. If the chemistry matters, state it in the order notes.
Does the Shore value describe the printed part?
Only for solid material. A printed part with walls and infill feels softer than its nominal hardness, and the measured value depends on the wall count and where it is measured. If hardness must be verified, have solid test samples printed or agree on the measuring method in the quote.
Can printed TPE parts seal?
For low-pressure prototypes and covers, often yes, with enough perimeters and a sealing face that runs along the layers. Layer seams can leak and TPE takes a set under sustained compression, so validate printed seals and use molded silicone for long-term sealing.
What is the route to higher quantities?
FDM suits single parts and small batches. For tens to about 200 parts with a production-like surface, cast polyurethane in silicone molds is a common bridge; beyond that, injection molding of a thermoplastic elastomer, or LSR for seals, takes over. Once the design is stable, Uretyco can compare the routes.
Related resources
- TPU 95AFirmer, tougher flexible material.
- Liquid Silicone Rubber (LSR)For seals, heat and long-term compression.
- Cast PolyurethaneSmall batches across a wide hardness range.
- 3D PrintingChoosing between FDM, SLA, SLS and MJF.
- Silicone MoldingSoft elastomer tooling paths.
- Material Selection GuideStart from the requirement, not the material name.
Related materials
Elastomers
TPU 95A
Tough, abrasion-resistant thermoplastic elastomer with a firm, rubber-like Shore 95A hardness. Printed by MJF or FDM, or injection-molded, for grips, bumpers, covers, light-duty seals and cushioning.
Elastomers
Flexible Resin
Soft, rubber-like photopolymers from about Shore 50A to 80A that bend, stretch and spring back. For soft-touch prototypes, small seals, grips and fine elastic details; less tear- and abrasion-resistant than TPU or silicone.
Elastomers
PolyJet Rubber-like
Flexible photopolymer jetted alone or mixed with rigid material to reach about 30–95 Shore A. Suited to overmold-style prototypes, soft-touch grips and seals for fit tests; low tear strength and aging limit it to prototypes.
Plastics
PLA
Bio-based thermoplastic and the easiest FDM material to print: stiff, accurate and low-warp, but brittle and soft above about 50–55 °C. The default for visual prototypes, fit checks and indoor fixtures that never get warm.
Plastics
ASA
Weather-resistant styrenic: ABS-like toughness and processing, with an acrylate rubber that resists UV yellowing and embrittlement. The default for outdoor housings and trim, from FDM prototypes to injection-molded production.
Composites
CF-PLA
PLA filled with chopped carbon fiber: stiffer, lower-warp and with a fine matte finish, but more brittle than plain PLA and still limited to about 50–55 °C. For stiff jigs, fixtures and premium-looking indoor parts.
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