Processing Santoprene™ TPVs

Santoprene™ thermoplastic vulcanizates (TPVs) offer a variety of performance and processing advantages over conventional thermoset rubber. Learn about the many processing possibilities by selecting a process below. And be sure to check out the many case studies, technical and troubleshooting tips and other helpful materials in the “Learn More” section within each process.

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Simple illustration of injection molding process for Santoprene TPV

injection molding and processing tips

Santoprene™ TPVs combine processing advantages of a thermoplastic with the performance characteristics of thermoset rubber. Santoprene TPV grades can be easily and efficiently processed using conventional thermoplastics injection-molding equipment at reduced cycle times compared to thermoset rubber. The TPV flexibility allows for greater freedom of mold design where undercuts are employed.

Simple illustration of insert molding process for Santoprene TPV

insert molding and processing tips

Insert molding consists of placing a preformed substrate into the mold and injecting TPV around or over it. If the insert and the TPV are compatible materials, a melt bond occurs at the interface between the two materials. The strength of this bond is affected by several factors, including interface temperature, cleanliness of the insert and the melt temperature of the TPV.

Simple illustration of two-shot molding process for Santoprene TPV

two-shot injection molding and processing tips

TPVs can also be combined with polymers through several types of multi-shot injection molding processes. By combining multiple materials, an even wider variety of parts applications, such as a hard/soft combination, can be achieved. The process produces both a finished part and a substrate during each cycle. Two-shot molding is more efficient than insert molding because no handling of the substrate is required.

Simple illustration of blow molding process for Santoprene TPV

blow molding and processing tips

ExxonMobil offers TPV materials that can be extrusion blow-molded, allowing potential parts cost savings and design flexibility over traditional thermoset rubber parts for hollow parts. Santoprene TPVs can be blow molded in single layer, multi layer, exchange blow, sequential 3D, suction blow, flashless extrusion blow, injection blow and press-blow molding processes.

Simple illustration of blow molding process for Santoprene TPV

extrusion and processing tips

Santoprene TPVs are easy to extrude into single and complex profiles. Due to the nature of these materials, they have very good melt strength and exhibit low die swell. These materials can also be co-extruded to yield a part with both rigid and soft components. ExxonMobil has developed both chemical and patented water foaming technology to improve profile flexibility and reduce part weight.

Simple illustration of thermoforming process for Santoprene TPV

thermoforming and processing tips

The thermoforming properties of Santoprene TPVs are similar to ABS and exhibit good melt strength, which provides uniform and predictable sag characteristics during heating. When producing sheet for thermoformed parts, key attributes of Santoprene TPVs are maintained, including colorability, impact resistance, weatherability, excellent chemical resistance, non-skid, matte surface in appearance and feel.