TPO Foam XL
Grade
XL = chemically/electron-beam crosslinked sheet
Specify crosslinked TPO foam when fine uniform cells, good thermoformability and low compression set are needed.
Values for the XL condition
Other TPO Foam grades and fills
TPO Foam is listed in 10 conditions; see the grade overview at TPO Foam.
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 |
XLThis page 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 |
What is TPO Foam XL?
TPO Foam XL is TPO Foam in the XL grade — specify crosslinked TPO foam when fine uniform cells, good thermoformability and low compression set are needed. TPO Foam XL has a tensile strength of 0.4 MPa (0.058 ksi), weaker than 91% of polymer grades. Elongation at break is 170% and the elastic modulus is 0 GPa (1.6×10⁻⁴ Msi). TPO Foam XL 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). D45 is the default condition FabDigit quotes; XL is available on request or by drawing note.
Advantages
- Forms and bends easily — 90/100, better than 91% of polymer grades
- Lightweight — 0.05 g/cm³ (0.0016 lb/in³), better than 90% of polymer grades
- Good corrosion resistance — 90/100, better than 82% of polymer grades
Limitations
- Low stiffness — 0 GPa (1.6×10⁻⁴ Msi), worse than 97% 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 XL properties
Typical room-temperature values for TPO Foam XL; 19 are specific to this condition. Other listed values are TPO Foam reference data and may not represent this condition. Bars are the position among polymer grades.
Physical4
TPO Foam XL 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 XL has a tensile strength of 0.4 MPa (0.058 ksi), weaker than 91% of polymer grades. Elongation at break is 170% and the elastic modulus is 0 GPa (1.6×10⁻⁴ Msi).
Thermal8
TPO Foam XL is rated for continuous service to 100°C (212 °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 XL has an electrical resistivity of 1×10¹³ Ω·m.
Chemical & Environmental3
Corrosion resistance is excellent (90/100), better than 82% of polymer grades. UV resistance is fair.
Sustainability4
Producing a kilogram of TPO Foam XL 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 XL's machinability is good (62/100, better than 60% of polymer grades); weldability fair (45/100); formability excellent (90/100).
Values are nominal handbook figures for design screening. Confirm any required mill or lot documentation when quoting.
Working with TPO Foam XL
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.
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.
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 |
TPO Foam XL — frequently asked
What is TPO Foam XL used for?
TPO Foam XL 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 XL?
TPO Foam XL has a typical tensile strength of 0.4 MPa (0.058 ksi) — weaker than 91% of polymer grades. Strength varies by condition: see the 10 listed tempers.
Is TPO Foam XL easy to machine?
Reasonably — machinability is rated good (62/100, better than 60% 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 XL be welded?
With care — weldability is rated fair (45/100). 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 XL?
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 XL 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 XL?
TPO Foam XL is rated for continuous use to about 100°C (212 °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.
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. Nothing on this page is a certification — request mill certs, CoC or material test reports with your order.