Jul. 07, 2025
Discover the key differences between TPE and TPU for 3D printing. This guide includes a free performance comparison chart, practical use cases, and expert tips from Unionfab to help you choose the best flexible material for your project.
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When it comes to 3D printing flexible materials, TPE (Thermoplastic Elastomer) and TPU (Thermoplastic Polyurethane) are the top contenders. Both are elastomers—offering stretchability, flexibility, and shock absorption—but they differ significantly in structure, print behavior, and performance.
This blog provides a complete comparison of TPE vs TPU, tailored for engineers, designers, and manufacturers working with 3D printing. From core material properties to real-world Unionfab use cases and printability insights, you'll find everything you need to choose the right material for your next project.
TPE (Thermoplastic Elastomer) is a blend of polymers that behaves like rubber but processes like plastic. It’s soft, flexible, and commonly used in products that require comfort, grip, or cushioning.
TPU (Thermoplastic Polyurethane) is a subtype of TPE known for its excellent toughness, abrasion resistance, and elasticity. TPU can be either soft or semi-rigid, depending on its formulation, and is favored for its durability.
TPE and TPU differ significantly in their molecular structure, which directly affects their physical behavior and suitability for 3D printing.
TPE is typically a polymer blend, made from soft rubber phases like SBS, SEBS, or TPV combined with rigid plastic phases such as PP or PS. The combination influences material properties: for example, SEBS-based TPEs offer better UV resistance, while TPVs deliver enhanced heat resistance.
TPU, on the other hand, is a block copolymer, made from alternating hard segments (diisocyanate + chain extenders) and soft segments (polyether or polyester). Polyether-based TPUs are more hydrolysis-resistant and flexible, whereas polyester-based TPUs offer better abrasion resistance but are more prone to hydrolysis.
TPU: Tightly packed polyurethane chains → tougher, more resilient, and chemically resistant
TPE: Overmolded grips, ergonomic handles, vibration dampers, soft wearables
TPU: Wear-resistant components, protective casings, mechanical connectors, flexible hinges
The following table highlights key mechanical and thermal properties that influence printability and end-use performance:
TPE in Medical Devices: TPE is highly valued in the medical industry for its chemical inertness and biocompatibility. It is commonly used in the manufacturing of medical components such as tourniquets, breathing masks, medical tubing, and infusion sets.
TPU in Wearable Medical Devices: TPU is used to manufacture wristbands and straps for wearable medical devices. It is hypoallergenic, comfortable for skin contact, and offers excellent flexibility for long-term use.
TPE in Cable & Audio Lines: With its excellent flexibility and surface finish, TPE is a go-to material for USB cables, headphone wires, and jack housings where flexibility and aesthetics are key.
TPU in Rollable Electronics: TPU’s elasticity makes it ideal for rollable and foldable electronics. It has been used as the outer shell and internal structure for devices like rollable OLED TVs.
One of Unionfab’s most popular applications of TPU is in the production of flexible shoe soles, combining abrasion resistance and elasticity. Using SLS technology, we helped a footwear brand develop a lightweight, shock-absorbing sole that maintains flexibility under repeated compression—ideal for performance and casual wear alike.
In another creative example, we 3D printed a squishy puffer fish toy using ultra-soft TPE. The model demonstrates how TPE can be used not only for function but also for tactile user experience. The material offered just the right rebound and softness for an engaging prototype that mimicked real-life squish behavior.
Both materials are printable, but their behavior differs significantly depending on printer setup and print parameters.
TPU is available in different Shore A hardness levels, and this greatly affects printability and performance:
60A TPU: Extremely soft and elastic; difficult to extrude consistently. Not recommended for FDM.
85A TPU: Balanced flexibility and printability; suitable for insoles, soft enclosures, protective pads.
95A TPU: Near-rigid behavior; excellent for industrial-grade parts requiring abrasion resistance and structural shape.
When it comes to flexible materials like TPU, the choice of 3D printing method significantly affects print quality, production speed, and application suitability. Three of the most commonly used methods for TPU are SLS, FDM, and MJF.
Selective Laser Sintering (SLS)
TPU is ideal for producing parts with complex geometries because it doesn’t require support structures during printing. This makes it especially suited for applications like wearables, sports gear, and medical devices where organic shapes and fine detailing are essential.
SLS TPU parts also tend to have excellent surface finish and mechanical performance right out of the printer.
Fused Deposition Modeling (FDM)
TPU is widely used in FDM printing due to its availability in filament form. However, print results vary depending on printer configuration. Direct-drive extruders are highly recommended, especially when working with softer TPU grades, since Bowden extruders may struggle to maintain filament control.
When configured correctly, FDM offers a cost-effective and accessible way to produce flexible components for functional prototyping or small-batch runs.
Multi Jet Fusion (MJF)
Multi Jet Fusion (MJF) by HP is a more recent method used for producing TPU parts in large volumes. MJF excels in speed and scalability, making it ideal for mass-customized products such as shoe soles, soft robotics, and industrial damping pads. It also offers good dimensional accuracy and repeatability with minimal post-processing.
To learn more about each method’s tradeoffs and real-world examples, check out our deep dive on TPU printing: TPU 3D Printing: Tips, Tricks & Best Solutions ().
For material safety considerations, refer to: Is TPU Toxic? What You Need to Know.
TPE (FDM):
Requires direct-drive extruder
Very soft = risk of jamming
Print slowly (20–30 mm/s)
Difficult with retraction → oozing possible
Best for experienced users
TPU (FDM/SLS):
Easier to feed due to slightly higher rigidity
Compatible with both direct and Bowden setups
Great for functional parts with excellent layer adhesion
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Ideal for both prototypes and production
TPE and TPU also differ in how they respond to surface treatment:
TPU is more receptive to coatings such as paints and adhesives, making it suitable for colored finishes or custom texturing.
TPE has a more rubbery surface, which can be difficult for paint or adhesives to bond with, requiring specialized primers or surface treatments.
Spray painting (TPU recommended)
Tumble polishing (for MJF/SLS parts)
Color dyeing (especially effective for SLS TPU)
Surface sealing/coating for improved wear or waterproofing
Unionfab offers a wide range of professional finishing services for flexible materials, including coloring, polishing, and advanced coating solutions for industrial use.
Learn more about available finishes in our Post-Processing Capabilities.
Both materials exhibit high shrinkage, so accurate dimensional compensation is essential.
Supports may not always be required due to flexibility, but part orientation matters greatly.
Explore our 3D Printing Materials Guide for more technical insights.
Not sure which material fits your needs? Start with these key questions:
Both TPE and TPU are excellent flexible materials, but their differences matter—especially in 3D printing.
Choose TPE if you need a soft-touch, ergonomic product and are working with a direct-drive printer.
Choose TPU if your part needs to withstand wear, chemicals, or repeated mechanical stress, or if you want an easier print experience.
The right choice will reduce trial-and-error and improve both print quality and end-use performance.
At Unionfab, we help you go from design to production with precision 3D printing of TPU and TPE materials. Whether you're testing a prototype or manufacturing complex flexible components, our team ensures the right material, technology, and support.
Use Our Free 3D Printing Cost Estimator
Contact Our Engineers for Expert Advice
What is the main difference between TPE and TPU?
TPE is a polymer blend that is softer and easier to stretch, while TPU is a type of block copolymer with superior durability, abrasion resistance, and better printability in most 3D printing technologies.
Can TPE and TPU be used in 3D printing?
Yes, both TPE and TPU are 3D printable, but TPU is more stable and easier to use—especially with FDM and SLS printers. TPE requires more careful handling and often a direct-drive extruder.
Which is more flexible, TPE or TPU?
TPE is generally softer and more elastic. However, TPU offers a better balance of flexibility and toughness, making it suitable for functional applications.
Is TPU more expensive than TPE?
Yes, TPU typically costs more than TPE due to its enhanced mechanical properties and broader industrial applications.
Which material is better for functional parts?
TPU is preferred for functional 3D-printed parts because of its superior wear resistance, elasticity, and chemical durability.
Can I color or paint TPE and TPU parts?
Yes. TPU is easier to post-process and coat, while TPE may need special surface treatment to hold paint or adhesives effectively.
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MatterHackers PRO Series materials are formulated for functional 3D printing. Because of its precisely detailed chemical blueprint, PRO Series 3D printing filament provides the consistency needed for repeatable part-production. Kawasaki’s Supercross Racing Team Engineers use PRO Series materials for both prototyping and end-use parts. Using PRO Series materials for essential components on their teams’ motorcycles has not only helped them fabricate in low volume, but it’s also reduced cost by 95% and time by 86%. They turn to PRO Series because they know it works well.
PRO Series materials are formulated with zero compromises. The base resin, and all performance-enhancing additives, are carefully sourced to include only those of the highest purity and provenance The consistent colors curated from quality sources combined with the exact manufacturing environment needed to maintain an industry-leading ±0.02mm diameter tolerance create materials you can use confidently. Experience smooth, uniform filament for all your important projects - experience PRO Series.
PRO Series TPU is a great choice for parts that need a high impact resistance
Not only is our PRO Series line of filament carefully crafted, but we have an extensive collection of materials to choose from that fit every need and specific applications. From Tough PLA for serious prototyping to vibrant Nylons for sturdy, lasting products, PRO Series 3D printing materials deliver quality parts, time after time. PRO Series filament is created with end-use results as the main priority, ensuring that your finished 3D printed parts are as clean, sturdy, and functional as possible.
MatterHackers PRO Series filament has remained the quintessential choice for anyone that demands exacting results for their business, products, and projects. Our attention to precise filament tolerance, strict coloration guidelines, and definitive chemical patterns are reflected directly in your completed products.
We know that end-use products are only as good as the materials and tools used to create them - that’s why we put our PRO Series filament through rigorous testing before it makes its way to your workshop or manufacturing floor. Having high-quality materials is essential when creating functional or product-ready components, therefore all MatterHackers PRO Series materials are analyzed using in-house testing equipment, including a Universal Testing System and a Melt Flow Indexer. These machines are used specifically to measure tensile and flexural properties, as well as the melt flow index of each material ensuring that all PRO Series filament is dependable and performing at its peak capabilities. MatterHackers PRO Series materials are tested and measured using ASTM 638 and D790 or ISO 527-1, 527-2, and 178.
With PRO Series materials, you know you’re getting the most accurate filament diameter and ovality available. Having a consistent diameter of 3D printing filament is very important - it directly impacts the print quality of your designs. The slicing engine calculates the volume of filament that will be deposited on each layer. The critical value that is input into the slicing engine for that volume is the diameter of the material (either 1.75mm or 2.85mm). Therefore, any variation in that diameter can cause the print to over or under extrude. In terms of raw materials - the filament diameter is one that requires a high level of confidence that you KNOW what you’re using.
Since we know diameter matters, we obsess over ensuring that PRO Series materials are on the mark so you can create perfectly printed parts. MatterHackers uses two and three-axis laser systems to measure and maintain the accuracy of the filament diameter at 40 hertz (40 times per second) - that way we know the filament diameter is consistent and within our 0.02mm diameter tolerance guarantee. Not only that, but the data for each production run is recorded and stored so we have traceability on all PRO Series materials to establish further confidence in each batch we produce.
Rest assured knowing that MatterHackers controls and actively analyzes the compounding and coloration of each filament batch, ensuring that your projects are the same from spool to spool. Color continuity between batches is controlled and confirmed with a color-analyzing spectrometer running in line during filament production. Your PRO Series filament will always be the same color PRO Series filament.
Technical Specifications
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