In markets from automotive to medical devices, manufacturers demand materials that blend elasticity, chemical resistance, and manufacturability. Santoprene™ thermoplastic vulcanizate (TPV) achieves that balance. It behaves like EPDM rubber under stress but can be processed like a thermoplastic via extrusion, thermoforming, or injection molding.
At SantopSeal Corporation, we specialize in manufacturing and supplying Santoprene sheets and custom extrusions geared for thermoforming, sealing, and structural applications. Our stock covers multiple grades, and we offer custom thicknesses and widths (up to 36″) to match your design and volume needs.
Santoprene TPV: Material Fundamentals & Properties
What is TPV / Santoprene?
It is a dynamically vulcanized blend: cured rubber (often EPDM) dispersed in a thermoplastic matrix (commonly polypropylene).
The crosslinked rubber phase gives elasticity and fatigue resistance; the thermoplastic phase enables extrusion, recycling, and thermal processing.
Santoprene can be extruded as a sheet roll at a various thickness and then can be processed in the thermoforming machine make any custom thermoformed parts as per specific application requirement.
Below is what the Santoprene TPV sheets looks likes.
Key mechanical & thermal properties:
| Property | Typical Range / Behavior | Why It Matters |
| Temperature window | 175–230 °C for processing (350–450 °F) | Enables thermoforming, extrusion, remelt processing |
| Flex fatigue & elasticity | Excellent retention over repeated cycles | Critical for seals, gaskets, moving parts |
| Chemical & weather resistance | Good resistance to oils, UV, ozone | Maintains long-term performance outdoors or near engines |
| Recyclability | Material can be ground and reprocessed (within limits) | Reduces waste and cost in prototyping & production |
Grades of Santoprene Ideal for Thermoforming
Here are a few grades out of many available that support sheet extrusion and thermoforming in practice. Use these as reference points; always check the latest datasheets for your precise application.
Celanese offers various Santoprene grades suitable for thermoforming, with specific options available for different applications: below mentioned are few grades out of many available.
- SANTOPRENE™ 8201-90: This is a hard, colorable TPV grade recommended for sheet extrusion and thermoforming. It offers good physical properties and chemical resistance.
- SANTOPRENE™ 101-73: A softer, colorable TPV, this grade is suitable for sheet extrusion and thermoforming. It is recommended for sealing and glazing applications.
- SANTOPRENE™ TPV 103-40: This versatile TPV grade is designed for processing via injection molding, extrusion, and thermoforming. It has a high melt viscosity at low shear rates, which can be optimized with smaller gates and higher shear rates for improved melt flow.
- SANTOPRENE TPV 101-87
- SANTOPRENE 121-73W175
Applications That Benefit from Thermoformed Santoprene Sheets & Extrusions
Below are real-world scenarios where using thermoformed TPV offers strong advantages:
- Under-hood air ducts and covers
- Vibration-damping panels
- Flexible seals, grommets, and interior trim parts
- TPV enables weight savings vs thermoset rubber and allows integration into mixed-material assemblies.
- Window and door seals
- Curtain wall gaskets
- Expansion joints
- These require weather, UV, and temperature durability, strengths of Santoprene.
Electrical, Enclosures & Flame-Retardant Needs
- Enclosure lids and covers
- Cable jacketed sectors
- Components needing UL or flame ratings
- Fire-retardant TPV grades Santoprene 251-92W232 support these requirements.
Plumbing, Fluid Systems & Potable Applications
- Housing covers, sealing components
- Wet-environment surfaces
- Santoprene 241-64 is NSF-51 and NSF-61 rated for potable water use and suited for thermoforming and extrusion.
- Soft-touch grips
- Seals and gaskets in appliances
- Lightweight flexible housing components
- Medical- and food-safe Santoprene grades exist for these use cases.
Challenges & Tips in Thermoforming Santoprene Sheets
- Uniform heating & control : Because Santoprene contains rubber and thermoplastic phases, overheating or underheating causes defects. Use zoned heating and precise control.
- Springback and elastic recovery: After forming, some elastic rebound is expected. Design molds and shrink allowances accordingly.
- Depth limitations: Deep draws may thin walls or strain material. Use gentle draws or assist mechanisms (e.g., plug assist or pressure forming).
- Thickness and sheet stability: In thick sheets, temperature gradients can occur. Keep thickness reasonable or preheat gradually to reduce stress.
- Tooling surface & compatibility: Smooth molds, proper draft angles, and compatibility with elastomers are essential.
- Material selection & grade matching: Pick the right Santoprene grade based on hardness, chemical/temperature exposure, safety rating, and formability.
SantopSeal’s Offering: Custom Santoprene Sheets & Extrusions
At SantopSeal Corporation, we deliver Santoprene thermoplastic sheets that support your design and manufacturing goals:
- Custom Santoprene sheet thickness
- Custom TPV sheet width up to 36″ for large part fabrication
- Multiple grades available – from soft sealing grades to rigid, flame-retardant, potable-water-safe grades
- Extruded parts & profiles – seals, gaskets, tubing, custom cross-sections extruded profiles
- Technical support – aid in grade selection, forming parameters, tolerances
We maintain quality control on extrusion flatness, dimensional stability, and color consistency to ensure your thermoforming works first time.
Contact us at info@santopseal.com or at +1-412-444-1888 to discuss your requirements of Standard or custom Santoprene TPV sheets.