TPE FOAM
Grade
also Santoprene-like TPE
FOAM = foamable / low-density TPE
Weight- and cost-driven soft seals, sponge-like grips and acoustic parts using chemical or physical foaming.
Values for the FOAM condition
Other TPE grades and fills
TPE is listed in 10 conditions; see the grade overview at TPE.
Compare all 10 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
FOAMThis page Foamable / low-density TPE | Weight- and cost-driven soft seals, sponge-like grips and acoustic parts using chemical or physical foaming. | — | 3 | 250 | 10 Shore D |
Very soft grade | Choose for low-closure-force gaskets, soft-touch grips and bellows where sealing on light load is critical. | — | 5 | 400 | 9 Shore D |
Soft general purpose | Balanced softness and tear strength for overmolded handles, cable strain reliefs and static seals. | — | 6 | 450 | 14 Shore D |
Halogen-free flame-retardant TPE | Pick for cable jackets, connector seals and appliance parts requiring UL 94 V-0 without halogens. | — | 7 | 300 | 26 Shore D |
Overmolding / bondable grade | Two-shot or insert overmolding on rigid substrates where peel adhesion, not just softness, governs the design. | — | 7 | 520 | 17 Shore D |
Shore A 30 to Shore A 90Default Shore A 30–90 | Default catalogue entry covering the standard soft-to-hard injection grades; pick a specific Shore point when sealing force or feel matters. | — | 8 | 480 | 20 Shore D |
Medium hard general purpose | Workhorse hardness for automotive weather-seal inserts, plugs, bushings and durable grips. | — | 9 | 500 | 22 Shore D |
Hard grade | Use where higher stiffness, abrasion and load support are needed, e.g. wheels, dust boots, semi-rigid seals. | — | 12 | 550 | 28 Shore D |
Very hard elastomer grade | Top of the Shore A range for stiff bellows, pipe seals and parts needing near-rigid feel with some flex. | — | 17 | 600 | 36 Shore D |
Rigid TPE / TPV grade | Semi-rigid grade for structural flexible parts, air-duct bellows and living-hinge components replacing soft PP. | — | 23 | 500 | 40 Shore D |
What is TPE FOAM?
TPE FOAM is TPE in the FOAM grade — weight- and cost-driven soft seals, sponge-like grips and acoustic parts using chemical or physical foaming. TPE FOAM has a tensile strength of 3 MPa (0.363 ksi), weaker than 84% of polymer grades. Elongation at break is 250% and the elastic modulus is 0 GPa (4.35×10⁻⁴ Msi). TPE FOAM has a density of 0.7 g/cm³ (0.0253 lb/in³), lighter than 83% of polymer grades. Its glass-transition temperature is -55°C (-67 °F). Shore A 30 to Shore A 90 is the default condition FabDigit quotes; FOAM is available on request or by drawing note.
Advantages
- Forms and bends easily — 95/100, better than 99% of polymer grades
- Lightweight — 0.7 g/cm³ (0.0253 lb/in³), better than 83% of polymer grades
- Good UV / weathering resistance — 70/100, better than 83% of polymer grades
- Ductile — tolerates forming and impact — 250%, better than 79% of polymer grades
Limitations
- Difficult to machine — 18/100, worse than 98% of polymer grades
- Hard to polish — 20/100, worse than 95% of polymer grades
- High mold shrinkage — 2.5%, worse than 93% of polymer grades
- Low stiffness — 0 GPa (4.35×10⁻⁴ Msi), worse than 92% of polymer grades
- Poor heat conductor — 0.1 W/m·K (0.0578 BTU/hr·ft·°F), worse than 83% of polymer grades
TPE FOAM properties
Typical room-temperature values for TPE FOAM; 20 are specific to this condition. Other listed values are TPE reference data and may not represent this condition. Bars are the position among polymer grades.
Physical5
TPE FOAM has a density of 0.7 g/cm³ (0.0253 lb/in³), lighter than 83% of polymer grades. Its glass-transition temperature is -55°C (-67 °F).
Mechanical13
TPE FOAM has a tensile strength of 3 MPa (0.363 ksi), weaker than 84% of polymer grades. Elongation at break is 250% and the elastic modulus is 0 GPa (4.35×10⁻⁴ Msi).
Thermal10
TPE FOAM is rated for continuous service to 95°C (203 °F). It conducts heat at 0.1 W/m·K (0.0578 BTU/hr·ft·°F), worse than 83% of polymer grades. Thermal expansion is 200 µm/m·K (111.1 µin/in·°F).
Electrical5
TPE FOAM is an electrical insulator with a dielectric strength of 20 kV/mm (508 V/mil) and a resistivity of 1×10¹³ Ω·m.
Chemical & Environmental3
Corrosion resistance is excellent (85/100), better than 65% of polymer grades. UV resistance is very good.
Sustainability4
Producing a kilogram of TPE FOAM takes about 95 MJ of energy and emits 3.6 kg of CO₂ — less than 70% of polymer grades. Typical recycled content is 5%.
Manufacturability8
TPE FOAM's machinability is poor (18/100, worse than 98% of polymer grades); weldability good (60/100); formability excellent (95/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with TPE FOAM
Is TPE easy to machine?
Soft grades smear and tear — use sharp positive-rake tools, high speed with low feed, water-jet or die-cutting; freeze fixturing helps on Shore A <60.
Can TPE be welded?
Hot-plate, hot-air and IR welding to itself and to PP work well; ultrasonic welding is unreliable because the soft phase damps energy — adhesive bonding needs primer or plasma/corona pre-treatment.
Can TPE be formed, bent or molded?
Dry 1–2 h at 70–80 °C if wet, melt 180–235 °C, mold 20–60 °C, use generous gates/short shot paths, expect 1–3 % shrinkage and design for 2K adhesion or mechanical interlock in overmolding.
What surface finishes work on TPE?
Surface is defined by tool texture (EDM/laser texture reproduces well); no plating or anodizing — use in-mold color, laser marking or pad printing with elastomer-compatible inks.
TPE chemical composition (wt %)
Limits by weight percent from the governing specification, written the way the spec states them — a single maximum for impurities, a range for alloying elements, and the base element as balance. Nominal is the typical mid-range value.
| Element | Spec limit (wt %) | Nominal |
|---|---|---|
| polypropylene (PP hard phase)continuous thermoplastic matrix; sets Tm and stiffness | 25 – 50 | 35 |
| paraffinic process oilsoftener; higher oil = lower Shore A and lower oil resistance | 5 – 35 | 17 |
| filler (talc / CaCO3 / ATH in FR grades)0 in natural grades; ATH used for halogen-free V-0 | 0 – 40 | 2 |
| additives (antioxidant, UV stabilizer, p | 0.5 – 3 | 1.5 |
| EPDM rubber (dynamically vulcanized) or elastic phase; EPDM/TPV for heat+set, SEBS for feel and cost | ≥ 30 (balance) | — |
TPE FOAM — frequently asked
What is TPE FOAM used for?
TPE FOAM is typically used for overmoulded tool and appliance grips, static seals and gaskets, automotive interior weatherstrip, cable jackets and strain reliefs, soft-touch consumer electronics surfaces and grommets and bellows. In short: rubber-like flexibility.
What is the tensile strength of TPE FOAM?
TPE FOAM has a typical tensile strength of 3 MPa (0.363 ksi) — weaker than 84% of polymer grades. Strength varies by condition: see the 10 listed tempers.
Is TPE FOAM easy to machine?
Not especially — machinability is rated poor (18/100, worse than 98% of polymer grades). Soft grades smear and tear — use sharp positive-rake tools, high speed with low feed, water-jet or die-cutting; freeze fixturing helps on Shore A <60.
Can TPE FOAM be welded?
Yes — weldability is rated good (60/100). Hot-plate, hot-air and IR welding to itself and to PP work well; ultrasonic welding is unreliable because the soft phase damps energy — adhesive bonding needs primer or plasma/corona pre-treatment.
What surface finishes work on TPE FOAM?
Surface is defined by tool texture (EDM/laser texture reproduces well); no plating or anodizing — use in-mold color, laser marking or pad printing with elastomer-compatible inks.
Can TPE FOAM be formed, bent or molded?
Dry 1–2 h at 70–80 °C if wet, melt 180–235 °C, mold 20–60 °C, use generous gates/short shot paths, expect 1–3 % shrinkage and design for 2K adhesion or mechanical interlock in overmolding.
What is the maximum service temperature of TPE FOAM?
TPE FOAM is rated for continuous use to about 95°C (203 °F), and briefly to 135°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
Can FabDigit make parts in TPE FOAM?
Yes — TPE FOAM is available for injection molding; every part is priced by an engineer rather than instantly. Upload a STEP file to get a price and a DFM check.
Sources
- ISO 18064 — Thermoplastic elastomers, nomenclature and abbreviated terms — ISO (2014)
- ASTM D412 / D2240 / D624 / D395 — tensile, durometer, tear, compression set of elastomers — ASTM (2021)
- Santoprene TPV product family data (8000/100 series) — ExxonMobil / Celanese (2023)
- THERMOLAST K / HIPEX TPE compound datasheets — KRAIBURG TPE (2023)
- CAMPUS plastics — TPE-V / TPE-S injection grades — CWFG (2024)
- Handbook of Thermoplastic Elastomers / ASM Engineering Plastics — Elsevier / ASM International (2007)
- TPE/TPV (2026)
Property data is compiled from published supplier and standards handbooks and normalised for comparison. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.