TPO Foam
TPO Foam is a foamed blend of polypropylene and elastomeric olefin phases tested to ASTM D3575, giving rubber-like flexibility with polyolefin processability.
Reference datasheet — TPO Foam is not in the instant-quote catalog. Upload your part and an engineer will quote it in this grade or suggest the closest stocked equivalent.
Values for the D45 condition
TPO Foam grades and fills
TPO Foam is supplied in 10 conditions, soft to hard. D45 is the default FabDigit quotes; the values on this page are for it.
Compare all 10 grades and fillsHide
| Grade · open for datasheet | Best for | Yield MPa | Tensile MPa | Elong. % | Hardness |
|---|---|---|---|---|---|
33 kg/m³ | Common roll-goods density for interior trim backing and soft gasketing. | 0.13 | 0.28 | 140 | 16 Shore A |
25 kg/m³ | Pick for light cushion packaging and void-fill where softness matters more than load bearing. | 0.2 | 120 | 12 Shore A | |
60 kg/m³ | Use when the part must resist thermoforming stretch and carry higher gasket sealing loads. | 0.24 | 0.5 | 170 | 25 Shore A |
Non-crosslinked extruded foam | Lowest-cost route for packaging and protective sheet; coarser cells, higher set, fully re-extrudable scrap. | 0.28 | 130 | 18 Shore A | |
Flame-retardant grade | Choose where interior/rail/electrical burn tests (FMVSS 302, UL 94 HF-1) must be passed. | 0.3 | 120 | 24 Shore A | |
80 kg/m³ | Choose for repeated-impact pads, deep-draw thermoformed laminates and structural gaskets. | 0.34 | 0.7 | 180 | 30 Shore A |
D45Default 45 kg/m³ | Default all-round density: soft touch with usable load bearing for IP/door-trim laminates and sealing. | 0.35 | 150 | 20 Shore A | |
Chemically/electron-beam crosslinked sheet | Specify crosslinked TPO foam when fine uniform cells, good thermoformability and low compression set are needed. | 0.4 | 170 | 22 Shore A | |
100 kg/m³ | Pick for load-bearing spacers, anti-squeak/rattle pads and NVH parts needing firm resilience. | 0.45 | 0.9 | 190 | 35 Shore A |
Moldable expanded TPO bead foam | Use steam-chest molded bead foam for 3D energy-absorbing parts softer and more elastic than EPP. | 0.45 | 60 | 28 Shore A |
Supply forms, finishes and certifications
Ways TPO Foam is supplied — form, process route, surface or paperwork — without a datasheet of their own. The property values above apply.
| Option | What it is | Type |
|---|---|---|
ADH | Adhesive-backed (PSA laminated) sheet | Surface finish |
AS | Antistatic / ESD-safe foam | Coating |
UV | UV/heat-stabilized automotive grade | Grade option |
What is TPO Foam?
TPO Foam is a foamed blend of polypropylene and elastomeric olefin phases tested to ASTM D3575, giving rubber-like flexibility with polyolefin processability. Engineers select it where a softer, more resilient closed-cell foam than EPP is needed; it is available as crosslinked and non-crosslinked sheet, extruded plank and steam-chest molded bead parts. The 0.045 g/cm3 reference grade shows 0.35 MPa tensile strength, 150 % elongation, 0.038 W/m-K conductivity and about 95 C maximum service. The low-energy surface requires pretreatment before bonding; EPP is the stiffer alternative when energy absorption outweighs softness. TPO Foam has a density of 0.05 g/cm³ (0.0016 lb/in³), lighter than 90% of polymer grades. Its glass-transition temperature is -50°C (-58 °F). TPO Foam has a tensile strength of 0.35 MPa (0.0508 ksi), weaker than 92% of polymer grades. Elongation at break is 150% and the elastic modulus is 0 GPa (1.45×10⁻⁴ Msi).
What is TPO Foam used for?
- automotive interior soft-touch padding
- footwear midsole components
- sporting goods cushioning
- gasketing
- protective sleeves
Advantages
- Lightweight — 0.05 g/cm³ (0.0016 lb/in³), better than 90% of polymer grades
- Forms and bends easily — 85/100, better than 81% of polymer grades
Limitations
- Low stiffness — 0 GPa (1.45×10⁻⁴ Msi), worse than 98% of polymer grades
- Poor heat conductor — 0.04 W/m·K (0.022 BTU/hr·ft·°F), worse than 90% of polymer grades
TPO Foam properties
Typical room-temperature values for TPO Foam-D45; bars are the position among polymer grades.
Physical4
TPO Foam has a density of 0.05 g/cm³ (0.0016 lb/in³), lighter than 90% of polymer grades. Its glass-transition temperature is -50°C (-58 °F).
Mechanical9
TPO Foam has a tensile strength of 0.35 MPa (0.0508 ksi), weaker than 92% of polymer grades. Elongation at break is 150% and the elastic modulus is 0 GPa (1.45×10⁻⁴ Msi).
Thermal8
TPO Foam is rated for continuous service to 95°C (203 °F). It conducts heat at 0.04 W/m·K (0.022 BTU/hr·ft·°F), worse than 90% of polymer grades. Thermal expansion is 150 µm/m·K (83.3 µin/in·°F).
Electrical4
TPO Foam has an electrical resistivity of 1×10¹³ Ω·m.
Chemical & Environmental3
Corrosion resistance is excellent (88/100), better than 74% of polymer grades. UV resistance is fair.
Sustainability4
Producing a kilogram of TPO 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%.
Manufacturability6
TPO Foam's machinability is good (60/100, better than 51% of polymer grades); weldability very good (70/100); formability excellent (85/100).
Common Calculations4
Values are nominal handbook figures for design screening. Certified mill or lot data ships with every FabDigit order on request.
Strength versus weight in the polymer family
Yield strength against density for every polymer grade FabDigit runs. TPO Foam is highlighted; hover a dot for its name, or open the interactive family chart.
Working with TPO Foam
Is TPO Foam easy to machine?
Die cutting, kiss-cut, hot-wire, oscillating blade or waterjet all work; avoid conventional milling which smears and melts the cell walls.
Can TPO Foam be welded?
Joins by hot-air/impulse/ultrasonic welding to itself and to TPO skins; adhesives require flame, corona or plasma pretreatment because of the low-energy surface.
Can TPO Foam be formed, bent or molded?
Crosslinked sheet vacuum/press-forms at roughly 140–170 °C surface temperature; bead grades are steam-chest molded, non-crosslinked grades are extruded at about 175–215 °C melt.
TPO Foam 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 homo/copolymer)matrix phase | 45 – 75 | 60 |
| olefin elastomer (EPR/EPDM/POE)provides rubber-like softness and low-temperature flexibility | 20 – 50 | 33 |
| chemical blowing agent + crosslinker resomitted in physically (CO2/N2) foamed grades | 1 – 5 | 3 |
| talc / nucleant, antioxidant, UV & proce | 1 – 5 | 2 |
| flame retardant (FR grades only)ATH/phosphorus or brominated systems | 0 – 20 | 0 |
What surface finishes work on TPO Foam?
Cannot be painted or plated as a foam; use flame lamination, PSA transfer tape, textile/TPO skin lamination or embossing for the visible surface.
Equivalent designations
Standards and trade names that resolve to TPO Foam in FabDigit's catalog. Equivalence is nominal — check the exact specification when certification matters.
- Similar grades
- D3575
How much does TPO Foam cost?
TPO Foam is a premium-cost polymer ($$$), cheaper than about 51% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
TPO Foam — frequently asked
What is TPO Foam used for?
TPO Foam is typically used for automotive interior soft-touch padding, footwear midsole components, sporting goods cushioning, gasketing and protective sleeves. In short: softer than EPP; rubber-like closed-cell olefin; weldable to TPO skins.
What is the tensile strength of TPO Foam?
TPO Foam has a typical tensile strength of 0.35 MPa (0.0508 ksi) — weaker than 92% of polymer grades. Strength varies by condition: see the 10 listed tempers.
Is TPO Foam easy to machine?
Reasonably — machinability is rated good (60/100, better than 51% of polymer grades). Die cutting, kiss-cut, hot-wire, oscillating blade or waterjet all work; avoid conventional milling which smears and melts the cell walls.
Can TPO Foam be welded?
Yes — weldability is rated very good (70/100). Joins by hot-air/impulse/ultrasonic welding to itself and to TPO skins; adhesives require flame, corona or plasma pretreatment because of the low-energy surface.
What surface finishes work on TPO Foam?
Cannot be painted or plated as a foam; use flame lamination, PSA transfer tape, textile/TPO skin lamination or embossing for the visible surface.
Can TPO Foam be formed, bent or molded?
Crosslinked sheet vacuum/press-forms at roughly 140–170 °C surface temperature; bead grades are steam-chest molded, non-crosslinked grades are extruded at about 175–215 °C melt.
What is the maximum service temperature of TPO Foam?
TPO Foam is rated for continuous use to about 95°C (203 °F), and briefly to 120°C. Strength falls off well before that limit — check the elevated-temperature data for load-bearing parts.
What is the difference between TPO Foam D45 and TPO Foam D100?
D45 is the default condition — default all-round density: soft touch with usable load bearing for IP/door-trim laminates and sealing. D100: pick for load-bearing spacers, anti-squeak/rattle pads and NVH parts needing firm resilience.
How much does TPO Foam cost?
TPO Foam is a premium-cost polymer ($$$), cheaper than about 51% of the materials FabDigit quotes. Part price depends far more on geometry, tolerance and quantity than on the raw stock — upload a CAD file for a live quote.
Sources
- ASTM D3575 — Flexible Cellular Materials Made from Olefin Polymers — ASTM International (2020)
- UL 94 — Tests for Flammability of Plastic Materials (HBF/HF-1 foam categories) — UL (2021)
- Crosslinked polyolefin foam sheet product ranges (Alveolit/Alveolux type) — Sekisui Alveo (2023)
- Azote / Plastazote polyolefin foam technical data — Zotefoams (2023)
- Engineered Materials Handbook Vol. 2: Engineering Plastics (cellular polymers) — ASM International (1988)
- Polyolefin foam and TPO compound property records — CAMPUS / UL Prospector (2024)
- TPO/POE — 1688 / SMM (2025)
Property data is compiled from published supplier and standards handbooks and normalised for comparison; hardness values on non-Brinell scales are converted approximately for charting only. Manufacturability limits are FabDigit quote-engine defaults and may be relaxed by engineering review. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.