When engineering solutions for the automotive industry, thermoplastic vulcanizates (TPVs) are bound to be part of your process. TPVs have been gradually replacing thermoset EPDM rubber in automotive applications where elasticity and long-term performance are crucial and improvements in processing, design, and weight reduction are demanded. Today, there are dozens of TPVs available for a growing number of auto applications. So how can you achieve optimum performance most efficiently and at the right price point? The key is to understand which TPV technology is right for your specific application requirements. Our guide is designed to help you choose the best TPV in every situation so you get the performance you need without overbuying.
Understanding TPV in Automotive Applications
What Is Thermoplastic Vulcanizate (TPV)?
Thermoplastic vulcanizates (TPVs) are a class of thermoplastic elastomers (TPEs) that combine the elasticity and durability of rubber with the processing advantages of thermoplastics. Typically based on a dynamically vulcanized EPDM rubber phase within a polypropylene (PP) matrix, TPVs are designed as cost-effective, recyclable alternatives to thermoset rubber. They provide excellent flexibility, sealing performance, and resistance to heat, UV, and automotive fluids, making them widely used across automotive applications such as automotive sealing systems, air ducts, and underhood components.
Key Automotive Performance Requirements for TPV Materials
Selecting the right TPV for automotive applications requires evaluating performance needs across the component’s operating environment. Key considerations include sealing performance, resistance to heat, UV, weathering, and automotive fluids, as well as durability under vibration and long-term aging. Engineers also consider lightweighting, design flexibility, and compatibility with high-volume processing methods like extrusion, injection molding, and blow molding to meet both performance and cost targets in vehicle design.
How to Match TPV Grades to Automotive Requirements
Selecting the right TPV grade depends on aligning material properties with the specific performance requirements of the application. Factors such as temperature range, fluid exposure, flexibility, and processing method all influence which TPV formulation will deliver the best balance of performance and cost.
The table below provides a simplified guide to help match common automotive application requirements with appropriate Sarlink® TPV material series, making it easier to narrow down options and support material selection decisions.
Download a printable, shareable version of this table.
Automotive Application Requirements |
Application Examples |
TPV (EPDM+PP) Technology |
Attributes to Look For |
Optimized balance of cost and performance Minimal engineering requirements
|
Interior: Floor mats, bin mats, cup holder liners Chassis: Body plugs, fasteners, pressure relief valves, fuel filler neck, cable ducts, steering column seal |
General Purpose TPVs: |
Well-balanced flow characteristics for a good surface appearance and melt elasticity |
Consistent performance in demanding environments Increased requirements for thermal stability, chemical resistance, and exposure to mechanical stresses |
Under the Hood: air ducts, cuffs, grommets, vibration dampening, air guides, boots and bellows Chassis: fasteners, clips, bumpers, plugs, grommets |
High-Performance TPVs: Sarlink 4100 Series |
Excellent chemical and abrasion resistance Low tension and compression set Compression set property retention after heat aging Low oil swell Excellent flex fatigue resistance |
Class A surface requirements for molded parts UV stability for the life of vehicle |
Sealing Systems: Window encapsulation, inner and outer belt molded end caps, close out seals, cowl vent seals Under the Hood: air guides, hood scoop seals, lip seals Exterior: antenna seals / gaskets, mirror seals / gaskets, spoiler seals |
High Flow Molding TPVs: Sarlink 4700 Series |
High flow properties for hard-to-fill parts and a broad processing window UV resistance Low fogging Excellent surface appearance and aging performance Excellent dimensional stability (low shrinkage) |
Best in class surface appearance for critical class A surfaces For molded parts with long flow lengths UV stability for the life of vehicle Retained sealing force retention over time |
Sealing Systems: Window encapsulation, inner and outer belts, molded end caps, close out seals, cowl vent seals Under the Hood: air guides, hood scoop seals, lip seals Exterior: antenna seals / gaskets, mirror seals / gaskets, spoiler seals) |
Next Generation High Flow Molding TPVs: |
Super high flow properties and broad processing window Low tool fouling and aids in the reduction of surface blemishes (gate blush, tiger striping, sink marks, etc.) resulting from less than optimized tooling UV resistance Low fogging and odor Excellent surface appearance and aging performance Excellent dimensional stability (low shrinkage) |
Best in class lifetime UV performance for extruded seals Color-fastness Class A surface appearance |
Sealing Systems: glass run channels, belt line seals, hood to cowl seals, roof ditch molding, door gap filler seals, lower door seals, under hood seals
|
High Performance Extrusion TPVs: |
Optimum extrusion performance due to well-balanced rheological properties for a broad processing window with good melt strength Best in class UV stability Low fogging and exceptional color retention without blooming Optimal surface appearance due to controlled morphology Excellent long-term recovery behavior |
EPDM alternative for weather seals and under hood applications Excellent elasticity Superior compression set and speed of recovery at room and elevated temperatures |
Sealing Systems: glass run channels, belt line seals Under the Hood: air guides, hood scoop seals, lip seals, air ducts, boots and bellows Exterior: antenna seals / gaskets, mirror seals / gaskets, spoiler seals Chassis: fasteners, clips, bumpers, plugs, grommets |
High Performance TPVs with Improved Elastic Recovery or “Snap”: |
Improved rebound versus standard TPVs Improved oil resistance versus standard TPVs |
Color matching UV resistance Color fastness
|
Interiors: bin mats, cup holders, buttons, knobs, grips Sealing Systems: hood to cowl seals Exterior: antenna seals / gaskets, mirror seals / gaskets, spoiler seals
|
High Flow, UV Stable, Colorable TPVs: |
Lighter, natural color providing improved colorability for custom colors Excellent haptics UV resistance Low odor and fogging Non-hygroscopic; pre-drying is not necessary High flow properties for improved molding Excellent dimensional stability (low shrinkage) |
TPV vs EPDM for Automotive Sealing Applications
Thermoplastic vulcanizates (TPVs) and EPDM rubber are both widely used in automotive sealing applications, but they differ significantly in processing, design flexibility, and overall system cost. EPDM is a thermoset rubber that requires curing, whereas TPVs achieve rubber-like sealing performance with melt-processability, enabling more efficient manufacturing and greater design flexibility.
As a result, TPVs are increasingly used in automotive sealing applications where manufacturers are looking to reduce weight, improve processing efficiency, and support recyclability. They can also be formulated to deliver strong resistance to heat, weathering, and automotive fluids, along with excellent long-term UV and color stability—an advantage in visible or color-matched components.
EPDM remains a proven solution for highly demanding sealing environments, particularly where extreme temperature resistance or legacy specifications are required. However, for many applications, TPVs offer a balanced combination of sealing performance, durability, and manufacturing advantages that support modern vehicle design.
Frequently Asked Question:
TPVs are commonly used in automotive sealing systems, air ducts, underhood components, and CVJ boots. They are selected for applications that require flexibility, heat resistance, and durable performance with efficient thermoplastic processing.
TPV can offer advantages over EPDM in automotive sealing applications, including improved processing efficiency, design flexibility, recyclability, and potential weight reduction. However, EPDM remains a strong choice for some high-temperature or legacy applications.
Yes, TPVs can be formulated for excellent UV and weather resistance, making them suitable for automotive sealing and exterior components where long-term durability and appearance are important.
Choosing the right TPV grade involves matching material properties to application requirements, including sealing performance, temperature resistance, UV exposure, chemical resistance, durability, and processing method. Contact a Sarlink TPV expert for assistance in material selection.
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