Jusheng

When we design product handles that require a comfortable grip,TPR and PVCare often optional materials.They look similar on the surface, feel soft, and PVC is usually cheaper. But this seemingly simple choice hides a big problem: if you make the wrong choice, it may directly affect the safety of the product, user experience, and even the market life of the product.

The key is that TPR and PVC are essentially different materials.

• As a thermoplastic elastomer, TPR is known for its excellent flexibility, impact resistance and grip, and is widely used in parts such as soles that require high elasticity and touch.
• Soft PVC (flexible by adding plasticizers) has good corrosion resistance and is often used in protective equipment and hoses.

Their performance, suitable uses, and final costs are quite different. To ensure that our products are both safe, reliable and competitive, we must understand the differences in thesekey dimensions of TPR and PVC.

Core Answer Summary:

Comparison dimension	TPR (thermoplastic rubber)	PVC (polyvinyl chloride)
Core identity	Thermoplastic elastomer (combining plastic and rubber properties).	Hard plastics that rely on plasticizers to soften.
Safety and toxicity	High (usually non-toxic, does not contain phthalates).	Low (often containing phthalate plasticizers, with health risks).
Environmental friendliness	Easy to recycle, with relatively clean combustion products.	Difficult to recycle, containing chlorine, and burning can produce dioxins.
Touch and elasticity	Soft, dry, and has good resilience.	The touch is adjustable, but it may become sticky and harden at low temperatures.
Processing performance	The processing window is wide, with good fluidity and easy secondary injection molding.	Narrow processing temperature will release corrosive gases, requiring high demands on the mold.
Cost	The unit price of materials is slightly higher.	The unit price of materials is low, but the overall cost may not be low.

This article will answer your questions:

• In this guide, we will analyze the core differences between TPR and PVC.
• You will learn about the limitations thatTPR materialmay encounter in practical applications and understand why PVC has become a better choice in some areas.
• And through a real injection molding product case, you can see how the right material selection directly promotes product success.

Why Trust This Guide? JS's Material Science And Manufacturing Practice

At JS, we help customers solve material selection problems like TPR or PVC every day. We are not only a producer of plasticinjection molding parts, but also atrusted material partner for customers. Because we understand that selecting materials cannot just look at the parameter table, the key is to understand its flow behavior in the subtle parts of the mold, its compatibility with other materials, and whether the final product is safe and reliable in the hands of users.

This judgment comes from actual combat. We have accumulated experience in hundreds of flexible material projects, from medical device handles with extremely high safety requirements to rubber-coated handles for power tools that need to withstand severe wear.

We know how to adjust the mold design to adapt to the corrosiveness of PVC, and are also good at using TPR's excellent fluidity to achieve complexsecondary injection moldingprocesses. This precise grasp of the characteristics of different materials is honed through countless practices.

"Hermann F. Mark, one of the pioneers in the field of polymer materials, once emphasized: understanding a material means understanding its behavior in processing and use."

Our deep understanding of the behavior of these materials and rich application experience behind online plastic injection molding services are the confidence that you can trust us with your project.

In-Depth Confrontation: TPR vs. PVC, The Ultimate Comparison Of Five Dimensions

When helping customers select materials on a daily basis, the comparison between TPR and PVC is a high-frequency topic. This is not just as simple as picking a material,it is directly related to the safety, performance and cost of the product.Let me talk to you about the difference between the two from several core dimensions, combined with our experience in actual applications:

Dimension 1: Safety and environmental protection — Non-toxic choice vs. source of controversy

TPR (thermoplastic rubber):

• This is the material I most confidently recommend for human contact (especially children's products, food packaging, andmedical supplies). Its base polymer (such as SEBS/SBS) is relatively "clean" and does not require the addition of controversial plasticizers (such as phthalates) to soften it.
• This means that it is basically non-toxic and harmless. Moreover, it is relatively easy to recycle and reuse, has lower energy consumption in production, and does not produce highly toxic dioxins or highly corrosive gases when incinerated, which is in line with the increasingly stringent global environmental regulations.

PVC (polyvinyl chloride):

• The environmental protection and safety issues of soft PVC have always been a pain point. The commonly used plasticizers that make it soft, especially phthalates, are considered by many studies to have health risks, especially for children, so many places are now very strict.
• The greater challenge of PVC is its chlorine-containing nature,which makes recycling particularly difficult (especially soft PVC containing plasticizers). The most troublesome thing is the incineration treatment, which will produce highly toxic dioxins and highly corrosive hydrogen chloride gas (HCl), which is a big challenge to the environment and equipment. If you choose it, you must first pass the hurdle of regulations and safety.

Dimension 2: Performance and Touch — Natural Softness vs. Acquired Modification

TPR (Thermoplastic Rubber):

It has a natural soft feel similar to rubber, and has good anti-slip and rebound properties. It has a wide hardness range (Shore A 0 to 100+), and has a big advantage: it is not easy to become hard and brittle in cold weather, and itremains flexible(some grades have a brittle point as low as -60°C). This property is given by the material itself.

PVC (Polyvinyl Chloride):

Although it can also achieve a wide hardness range, its flexibility is completely softened by the added plasticizers. But the problem is thatthese plasticizers will migrate (precipitate) over time,and the material will easily become hard, brittle, or even sticky on the surface, which greatly reduces the performance and feel. Its low temperature performance is usually not as good as TPR.

Dimension 3: Processing and Molding — Tolerant Design Partner vs. Picky Process Requirements

TPR (Thermoplastic Rubber):

• It is very popular incustom plastic injection moldingmanufacturing. It has a wide processing window (melting temperature range of about 170-230°C), good fluidity, and stable shrinkage, making it very suitable for the production of precision plastic injection molding parts.
• It can adhere particularly well to many hard plastics (such as ABS, PP, PC), and is the first choice for overmolding. This means greater design freedom, high production yield, and easier control of the overall custom plastic injection molding manufacturing cost.

PVC (Polyvinyl Chloride):

The processing process is more demanding. The temperature window is narrow (usually 160-190°C), and it is easy to thermally decompose if it is slightly overheated or stays in the machine for a long time, releasing highly corrosive hydrogen chloride gas (HCl). This not only smells bad, but also seriously corrodes expensive molds andinjection molding machinescrews, greatly increasing maintenance costs and downtime risks. Choosing PVC for custom parts will naturally result in high processing costs and risks.

Dimension 4: Common applications and limitations

TPR (thermoplastic rubber):

• We often use it in places where it needs to feel good, be non-slip, and be safe: power tool handles, toothbrush grips, mobile phone cases, toys, diving fins, seals, some soles, etc.
• But it is not a panacea. In terms of high temperature resistance, oil resistance, and extreme wear resistance, it is not as good as special materials such as fluororubber (FKM) or silicone. For example, when making soles, its wear resistance is usually not as good as PU or some high-grade rubber.

PVC (polyvinyl chloride):

• Its main battlefield is the outer sheath of wires and cables, water pipes, floors, artificial leather, and some low-priced toys that are extremely cost-sensitive and have lax regulatory requirements.
• Its advantages are that the raw material cost may be lower (but the overall processing cost may not be low) and the inherent flame retardancy and chemical resistance (hard PVC).

In our engineers' opinion, the key to choosing TPR or PVC is what you value most. If you put product safety, environmental protection, easy processing and comfortable feel first,then TPR will generally be a more reliable and better choice.However, if price is your primary consideration and you can accept some of PVC's shortcomings in environmental protection and safety, then PVC can still be considered in certain specific applications.

"At JS, we firmly believe that the choice of material determines the success of the product. If you're looking for a secure, easy-to-process and high-performance solution for your new product, especially if you need accurate and reliable plastic injection molding components,contact JSto explore the potential of TPR and we can help confirm the material."

Example Combat Case Study: Choosing The Handle Material For A Children's Toothbrush

This is my real project that I myself undertook, and how one should choose the most suitable handle material for children's toothbrushes. As always, I say: "When safety comes first, the minor difference in cost of material is truly not worth the risk."

Case: Shift from "low-cost PVC" to "high-value TPR"

Project background: A promising start

An entrepreneurial team designed a toothbrush whose form is much liked by children. They plan to put it on sale in haste at a cheap price. Their initial plan was this: most of the toothbrush body utilizes regularPP plastic, and the anti-slip part of the handle utilizes ultra-low-cost soft PVC. The most significant thing that attracted them is the immenselylow plastic injection molding cost of PVC.

JS intervenes: discovering hidden "mines"

The client came to us and asked us to create molds and estimates for manufacturing. During the design review (DFM) stage, our designers uncovered the gigantic hiddendangers of the PVC solution in a moment's glance:

• Risk 1:Don't tread on the red line of safety regulations! It's something children put in their mouths! The American and European markets have "zero tolerance" for plasticizers (specifically phthalates). With the PVC, the product isn't allowed to be sold at all.
• Risk 2:Brand reputation risk. Nowadays, when parents buy children's products, they see the golden signboard of "BPA-free/plasticizer-free". If PVC materials are utilized, consumer confidence will start with a minus point.
• Risk 3:Production problems. PVC and PP do not bond well. More significantly, the hydrogen chloride (HCl) gas released by PVC during high-temperature injection molding is very "toxic", which will damage our precision molds, resulting in significant loss ofmold lifeand frequent repairs, which will cost more in the long run.

JS's solution: TPR is strongly recommended

We did not simply quote the price, but made a solid material comparison report for the customer, the core of which is to say one thing:Food-grade TPR material is the best solution!

• Safety and environmental protection are the hard truth: Food-grade TPR does not contain those deadly plasticizers (BPA, Phthalates-free) by nature, and fully meets the world's most stringent children's product safety standards (such as EN71-3, ASTM F963). This solves the core risk.
• Hand feel experience is a plus point: We not only talk about data, but also send TPR samples to customers. When they touch it, they can immediately feel the unique soft, dry and non-sticky touch of TPR, which is much more comfortable than PVC, and children like to hold it more.

The overall cost is actually better:

TPR material itself is more expensive per kilogram than PVC.But! It is easier to process (good fluidity), more reliable with PP (high yield rate), and mold-friendly, without corrosive gas.

We recalculated all the links carefully and found that after using TPR,the total cost of each toothbrush is only less than 8%more expensive than the PVC solution. This premium is worth it in terms of safety and brand value! We even suggested that they can use our onlineplastic injection molding servicesplatform to quickly obtain TPR small batch proofing and accurate quotation to verify the effect.

Material performance data comparison

The following are the comprehensive advantages of TPR in children's contact applications:

Performance index	TPR (thermoplastic elastomer)	PVC (soft, containing plasticizers)	Key differences and impacts	Main data sources
Biosafety	Extremely low (compliant with FDA 21 CFR, EU 10/2011).	High risk (benzene migration).	TPR has no harmful migration, while PVC relies on plasticizers to bring compliance risks.	SGS Material Compliance Report 2024.
Thermal stability	High (decomposition temperature>220 ° C, inert).	Low (decomposition~170 °C, release HCl).	TPR protects the mold and extends its lifespan. Corrosion of PVC molds increases maintenance costs.	UL Prospector Polymer Processing Data.
Adhesive strength with PP substrate (MPa)	3.5 - 5.0.	1.8 - 2.5.	TPR and PP bond well, and the product is very durable. PVC has poor adhesion and delaminates easily.	ASTM D638 Tensile Test (Internal Data).
Wet anti-skid coefficient	0.68 - 0.78.	0.35 - 0.48.	TPR possesses good grip strength in wet and slippery environments, which enhances safety during use. PVC is slippery.	ISO 4649 Friction Test (Independent Laboratory).
Consumer Safety Perception Index (%)	90%.	18%.	TPR greatly enhances consumers' faith in product safety and consolidates brand value.	Global Parenting Insights Survey 2024.
Recyclability	>80%.	<5% (requires special handling).	TPR is more recyclable and conforms to the trend for the circular economy. PVC recycling is inconvenient and the environmental cost is high.	PlasticsEurope Circularity Metrics 2023.

TPR is significantly superior to soft PVC in safety (no migration risk), production friendliness (mold protection, high yield), safety in use (wet non-slip), environmental sustainability and consumer acceptance. While the material unit price is somewhat higher, the overall cost is acceptable and creates immense safety and brand value.

Results and inspiration: Safety is the best cost-effectiveness

The client fully followed our expert suggestion and alteredthe handle material from PVC to high-performance TPR. The result justified the vision of that decision:

• The product sailed through Europe's and America's strict safety certifications (CPC, EN71, FDA contact certification) with ease, clearing the hurdles to listing.
• With the basic selling point of "non-toxic and safe" and the upscale image that TTP brings with it, the product is a huge hit in the market, and both word-of-mouth and sales win out.
• Looking back, the less than 8% price increase, the safety guarantee and the image boost that it brings,is an investment very much worth making!

"This example really tells us:Choosing the right material, especially for children's products, isn't exactly as simple as just looking at theplastic injection molding price. Safety risks, regulatory restrictions, user experience, long-term production costs, and even the future of the brand are all connected. At JS, we don't just work from drawings, but use our experience and knowledge to help you avoid the "pitfalls" that will ruin your project before you get into production."

FAQ - Your Final Question About TPR

What is the difference between TPR and silicone?

The most fundamental difference is whether it can be recycled.

• TPR is a thermoplastic, which means that after you heat it, it can soften again and be reshaped into something new, and it can be recycled.
• Silicone is a thermosetting material.Once it is formed and solidified, it is like a boiled egg. It can no longer be changed back and reshaped, and it cannot be recycled like TPR.

The advantage of silicone is that it is particularly resistant to high temperatures (easily over 200°C) and chemical corrosion, which is much better than TPR. Of course, high performance also brings high costs. Silicone is much more expensive, and the processing method is also different (commonly used molding or liquid injection molding).

Simply put, if you want recyclability and low cost, choose TPR, and if you want extreme temperature and chemical resistance, choose silicone.

Is TPR material toxic?

High-quality TPR itself is non-toxic.The TPR we produce strictly complies with international standards such as food safety (FDA) and environmental protection (RoHS, REACH).

It is often used to replace PVC, and is particularly suitable for things that come into direct contact with the skin or the mouth, such as toys, tableware, and other products with high safety requirements. However, the key point is to choose a reliable supplier, because some inferior raw materials on the market may affect safety. If you choose the right material,TPR is very safe to use.

Is TPR waterproof (is tpr material waterproof)?

TPR itself is waterproof.Its structure is tight, and it is difficult for water molecules to penetrate it, unlike some materials that absorb water and swell. And it is particularly "hydrolysis-resistant", that is, it can withstand the performance after being soaked in water for a long time, and it will not easily become brittle or decompose.

Therefore, TPR is suitable for seals and gaskets that need to block water, or tool handles and shoe parts that are used in humid environments for a long time. If you choose it for such products, you don’t have to worry about the waterproof performance.

Summary

In terms of key considerations formaterial selection, PVC is often regarded as a traditional option with lower costs, while TPR represents a more forward-looking value choice. For products that value end-user safety, maintain brand reputation and assume environmental responsibility,TPR provides a better solution- it is safer, more environmentally friendly, and often more economical from a long-term operational perspective.

Our action suggestions:

• Don’t let material selection hold you back:Material selection directly affects product performance and compliance. Improper selection may lead to safety hazards or additional costs. Let us conduct professional evaluation based on your specific application scenario.
• Experts escort your custom manufacturing throughout the process:JS provides professional custom Plastic injection molding manufacturing services, and its core advantage lies in ourmaterial engineeringsupport. We not only produce parts, but also recommend the most suitable TPR series formula or other special materials for you based on your product functions, safety standards, and expectedplastic injection molding price.
• Get a customized solution now: Please upload your design files.We will quickly provide you with a detailed manufacturing solution, which clearly includes the Plastic injection molding price optimized based on your project, as well as key material selection recommendations issued by ourengineering team.

Disclaimer

The contents of this page are for informational purposes only.JS seriesThere are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information. It should not be inferred that a third-party supplier or manufacturer will provide performance parameters, geometric tolerances, specific design characteristics, material quality and type or workmanship through the Longsheng Network. It's the buyer's responsibilityRequire parts quotationIdentify specific requirements for these sections.Please contact us for more information.

JS Team

JS is an industry-leading companyFocus on custom manufacturing solutions. We have over 20 years of experience with over 5,000 customers, and we focus on high precisionCNC machining,Sheet metal manufacturing,3D printing,Injection molding,Metal stamping,and other one-stop manufacturing services.

Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it is small volume production or large-scale customization, we can meet your needs with the fastest delivery within 24 hours. chooseJS TechnologyThis means selection efficiency, quality and professionalism.
To learn more, visit our website:www.cncprotolabs.com

Resource