What Is the Difference Between TPU vs TPE 3D Printing
- Tamara Arkhangelskaya
- 8 minutes ago
- 4 min read
When evaluating flexible materials for 3D printing, the conversation often comes down to TPE vs TPU. Both are elastomers used for flexible prints, but they’re not identical. In this post, we compare TPE and TPU based on data from eSUN’s technical data sheets.
If you are considering TPU and TPE 3D printing, this comparison may help clarify which material better suits your application.
Comparing TPE vs TPU Based on Real Data
Thermoplastic elastomers (TPE) and thermoplastic polyurethanes (TPU) are both flexible, rubber-like materials. But they differ in flexibility, strength, and handling. Let’s look at side-by-side results for eSUN’s filaments, based on their own published specifications.
Strength and Flexibility
The TPE vs TPU comparison from eSUN makes the differences clear. Both materials are flexible, but their performance characteristics diverge.
TPU has slightly higher tensile strength (35 MPa vs 32 MPa), making it more durable under load. Its standout feature, however, is the extreme elongation at break that is over 800%, compared to TPE’s 420%. This means TPU can stretch much further before tearing, which is great for parts that flex repeatedly, like cable sleeves or protective boots.
TPE remains the softer and more compliant option, with a lower Shore hardness (83A). This gives it a gentler feel and better damping for applications such as grips, seals, or comfort-focused components.
Density and Handling of TPU and TPE 3D Printing
The TPU vs TPE 3D printing data also shows TPU’s higher density (1.21 g/cm³) compared to TPE’s 1.14 g/cm³. This difference translates into slightly heavier prints and greater stiffness in thin sections. TPU also has a listed melt flow index, meaning it extrudes more predictably, while TPE’s lack of this measure reflects its softer, stickier behavior in extrusion.
TPU’s firmer Shore hardness (95A) and stable melt flow make it better suited for jobs where dimensional accuracy, repeatability, and surface finish matter. TPU’s structure provides more resistance to deformation, allowing better print precision and layer adhesion. It tends to produce smoother prints with fewer issues like stringing or inconsistent extrusion, which is particularly important when printing production-grade parts or customer-facing prototypes. This allows it to meet tight tolerances with less post-processing or rework.
TPE, though more elastic, can be more difficult to print consistently. TPE, while softer and more compliant, presents greater challenges in handling. Its increased elasticity can result in feeding problems or irregular extrusion if not carefully managed, especially on printers not tuned for such flexible materials. For this reason, we typically reserve TPE for simpler geometries or applications where high flexibility is the primary goal, and minor surface artifacts or shape irregularities are acceptable.
Where TPE or TPU Really Stands Out
To make the most of TPE vs TPU 3D printing, it’s helpful to ground the comparison in real applications. When selecting between TPE 3D printing and TPU, consider how the printed part will be used:
Choose TPE for soft-touch surfaces, vibration dampers, seals, and flexible prototypes that must deform comfortably. TPE’s soft surface makes it well-suited for shoe insoles, ergonomic grips, and vibration-isolation pads. In these cases, comfort, texture, and deformation behavior matter more than rigidity or tear strength. TPE’s lower Shore hardness gives these products a skin-friendly touch and better energy absorption under compression.
Choose TPU for high-stretch, tear-resistant parts exposed to mechanical wear, tension, or repeated bending. TPU is frequently used for phone cases, industrial gaskets, drone parts, and even drive belts. These parts must bend and flex without tearing, hold their shape across cycles, and resist wear. The higher elongation and improved durability of TPU make it better for designs where repeated stretching or strain occurs.
If your design depends on dimensional precision or thin-walled geometry, TPU 3D printing will maintain shape better.
For ergonomic parts where feel matters more than stiffness, TPE is the right fit.
Both materials can be used for FDM 3D printing effectively. The question of TPU vs TPE 3D printing is not about which material is universally better, but which material aligns with the function, environment, and expectations of your part.Â
Practical Considerations for TPU vs TPE 3D Printing
TPE and TPU share the same broad category but serve different needs.
TPU provides higher tensile strength, better elongation, and firmer recovery.
For TPE 3D printing, the material offers a softer, more tactile surface and easier deformation.
We provide 3D printing in Massachusetts and ship 3D printed parts nationwide. We also offer flexible resin 3D printing as an alternative when higher detail or a smoother surface is needed. For projects requiring maximum customization, we’re able to explore available filament or resin solutions to best match your application.
In many cases, testing and iteration are essential. Material properties on a datasheet offer a helpful starting point, but actual print results can vary depending on part geometry, environmental conditions, and mechanical expectations. We often recommend prototyping a few units before moving into larger production, especially when flexibility, fit, or tactile feel are critical to performance.
We’re here to help evaluate those variables and guide you to the most suitable and efficient material choice. If you need support for your project, we’re happy to discuss options in detail.