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A Polymer Invented in 1959 Is Still Enabling Innovation Across Multiple MarketsA Polymer Invented in 1959 Is Still Enabling Innovation Across Multiple Markets

A unique mix of strength, flexibility, and durability has made thermoplastic polyurethane a go-to material for applications in the automotive, medical, industrial, and many other sectors.

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thermoplastic polyurethane pellets
Thermoplastic polyurethane initially was developed for manufacturers that wanted a material that balanced the flexibility of rubber with the durability of metal. Image courtesy of Lubrizol

Editor’s note: Lubrizol, under the BF Goodrich name at the time, invented thermoplastic polyurethane (TPU) in 1959. The company celebrated the material’s 65th anniversary in 2024, and Senior Global Technical Business Development Manager Jennifer Green and Lubrizol Corp. Technical Fellow Anthony Walder took this opportunity to share with PlasticsToday some of the material’s milestones as well as the innovations it continues to bring to an array of end-use applications.

Green specializes in innovative material solutions for medical devices and healthcare applications. With more than 15 years in the industry, she has a deep understanding of polymer science and a passion for advancing biocompatible materials like TPUs and medical-grade silicones. She collaborates closely with medical device developers to enhance patient outcomes, focusing on sustainability, material performance, and regulatory compliance.

Walder has worked more than 35 years developing TPUs for medical and specialty non-medical applications. The process of developing TPU involves processing the materials into test specimens and considering making a device. Through experiences and solving others’ processing issues, Walder has refined the art of extrusion TPUs.

Ready for a deep dive into the past, present, and future of TPU? Let’s jump right in, then. 

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Give us a brief history of TPU. What are some of the major milestones?

Thermoplastic polyurethane, or TPU, was first invented by Lubrizol back in 1959 under the Estane TPU brand, back when we were known as BF Goodrich (Noveon International). Since then, we’ve kept pushing TPU’s boundaries, leading innovations like the first non-halogenated flame-retardant TPU and the first static-dissipative TPU. We have also achieved excellent weatherability, UV resistance, and color stability to make the material ideal for outdoor products. As the original inventor of TPU, we feel we bring experience, knowledge, and an extensive product lineup that is simply unmatched.

Initially, TPU was the answer for industries needing a material that could balance the flexibility of rubber with the durability of metal — a tough, adaptable material that could handle just about anything from industrial applications to healthcare and apparel. It has been improved, customized, and applied in the time since, in ways that have transformed many other industries.
For example, in the 1970s, TPU found its place in industrial and automotive uses, where it proved to be tough, resistant to chemicals, and able to stand up to heavy use. Then in the 1980s and 1990s, it became a favorite in sportswear and footwear when brands began using it in outsoles and midsoles for athletic shoes because it was flexible yet resilient — perfect for the wear and tear of running and training.

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TPU started making waves in healthcare by the 1970s, because here was a material that was not only strong and flexible but also biocompatible, making it a great fit for catheters and implants that need to be both durable and safe for use in the body. As the 1980s rolled around, it was becoming even more specialized. The 1990s saw the development of biostable polyurethanes. You’d find it in wound-care films, implantable devices, and even in drug-delivery systems, where its unique properties are put to work in ways that can be lifesaving.

Today you'll find TPU just about everywhere including everyday consumer products. What started as a simple but strong material has evolved into a go-to solution for all kinds of applications, and the technology is still evolving with many new possibilities on the horizon.

What are some of the current notable uses of the material? What benefits does it bring to these applications compared with other materials?

It's the unique mix of strength, flexibility, and durability that makes TPU essential to so many applications. In healthcare, medical-grade TPU is ideal because of its superior biostability and biocompatibility that enable it to handle sterilization and constant use without breaking down or causing irritation.

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In the world of wearables and electronics, TPUs are both tough and comfortable. They’re elastic and impact resistant, which is perfect for things like protective cases and flexible electronic parts that endure daily handling. People want their devices to last, but they also want them to be easy to wear or carry around, and TPUs help manufacturers deliver that balance.

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I already mentioned how the sports and footwear industries rely heavily on TPU, especially for athletic shoes. It’s ideal for midsoles and outsoles because it holds up under constant movement without losing flexibility. Unlike rubber, TPU doesn’t wear out as quickly, which makes it perfect for high-performing, highly durable footwear.

In automotive and industrial applications, abrasion resistance and flexibility make it an ideal material for cable jacketing, protective coatings, and other parts that are exposed to impacts or vibrations. While traditional rigid plastics can crack or wear down over time, TPU can flex and absorb movement, which makes it better suited for parts that need to handle a lot of stress.

In short, whether it’s healthcare, electronics, sports gear, or heavy-duty industrial uses, Lubrizol TPUs offer versatility and toughness that set them apart.

Are there any new applications in the pipeline that you can discuss?

There’s a lot happening right now as we explore new ways to use TPU. Sustainability is front and center. We have developed Lubrizol Bio TPUs with certified bio-based options, in accordance with ASTM D6866, derived from renewable resources and mass balance TPUs that keep the same performance, durability and flexibility people expect, but with a lighter environmental footprint. TPU is recyclable (where there is access to a readily available standard recycling program that supports such materials). In healthcare, TPU is starting to play a bigger role in drug-delivery devices, like implantable stents that release medication over time. Since the material is both biocompatible and able to degrade in a controlled way, it’s a great fit for getting medication directly to a targeted area without needing multiple interventions.

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Then there’s the world of microfluidics and diagnostics, where Lubrizol TPU’s chemical resistance and flexibility are invaluable. These diagnostic devices rely on tiny channels to move chemicals, and TPU keeps everything running smoothly without reacting or breaking down. In wound care, TPU films are also gaining attention because they’re flexible, breathable, and act as a barrier to bacteria while allowing moisture to escape, which helps wounds heal faster and lowers the risk of infection. Each of these areas shows how the material continues to adapt and meet new demands while holding onto the performance and dependability that made it popular in the first place.

You mentioned sustainability as a primary concern. Can you go into some more detail?

Sustainability is a priority for us, and it’s something our customers are asking for, too. That's why we’re committed to making TPU more sustainable, from production to end-of-life. Building off my previous comments, we have bio-based, mass balance, and recycled options that use renewable resources instead of fossil fuels or that incorporate recycled content.

In manufacturing, we’re focused on making our processes more efficient to reduce waste and conserve energy, which lowers emissions and helps us produce high-quality material with a smaller impact on the planet. 

While TPU is naturally durable, we’re always working to enhance its resilience, which helps cut down on waste by extending the life of each product.

At Lubrizol, we’re committed to responsible innovation that empowers our customers to meet their goals more confidently.

About the Author

Jennifer Green and Anthony Walder

Jennifer Green is the senior global technical business development manager at Lubrizol Life Sciences, where she specializes in innovative material solutions for medical devices and healthcare applications. With more than 15 years in the industry, Green has a deep understanding of polymer science and a passion for advancing biocompatible materials like thermoplastic polyurethanes (TPUs) and medical-grade silicones. She collaborates closely with medical device developers to enhance patient outcomes, focusing on sustainability, material performance, and regulatory compliance.

Anthony (Tony) Walder has worked more than 35 years developing TPUs for medical and specialty non-medical applications. The process of developing TPU involves processing the materials into test specimens and considering making a device. Through experiences and solving others’ processing issues, he has refined the art of extrusion TPUs. He is presently Technical Fellow at Lubrizol Corp.

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