Application Note
When Standard TPU Grades Fail in Film Extrusion Applications
TPU film extrusion projects often begin with standard grades that appear suitable during initial trials.
In many cases, samples pass basic evaluation, only to encounter instability, surface inconsistency,
or performance drift during continuous production.
These failures are rarely random and usually indicate structural limitations of standard TPU grades.
In many cases, samples pass basic evaluation, only to encounter instability, surface inconsistency,
or performance drift during continuous production.
These failures are rarely random and usually indicate structural limitations of standard TPU grades.
Application Context
TPU films are widely used in bedding protection, medical covers, breathable laminations,
and functional packaging.
While standard TPU grades are often sufficient for short trial runs,
film extrusion places unique demands on melt stability, surface uniformity,
and long-term process consistency.
and functional packaging.
While standard TPU grades are often sufficient for short trial runs,
film extrusion places unique demands on melt stability, surface uniformity,
and long-term process consistency.
Why Standard Grades Often Reach Their Limits
- Film extrusion amplifies small formulation differences that are insignificant in injection or profile extrusion.
- Surface smoothness during short trials does not reflect behavior under long, continuous runs.
- Standard grades are optimized for general processing windows, not narrow film extrusion conditions.
Typical Failure Signals in Film Production
- Thickness fluctuation and gauge instability over time.
- Surface haze, blocking, or unexpected tackiness after aging.
- Increased sensitivity to temperature and line-speed variations.
Common Misinterpretations
- “The sample looks fine, so the material is suitable.”
- “Film defects are mainly process-related.”
- “Any TPU can be adjusted through processing.”
When Material Adjustment Becomes Necessary
When film extrusion requires consistent surface quality, stable thickness control,
and predictable long-term behavior, standard TPU grades may no longer provide sufficient margin.
At this stage, compound-level adjustment or alternative supply approaches
should be evaluated systematically.
and predictable long-term behavior, standard TPU grades may no longer provide sufficient margin.
At this stage, compound-level adjustment or alternative supply approaches
should be evaluated systematically.
For TPU film applications where stability and surface consistency are critical,
material selection should extend beyond standard grades.
material selection should extend beyond standard grades.
Post time: Jan-12-2026