Thermoplastic Elastomers (TPEs) has been one of the most active areas in materials and application development. A recent market research study by Freedonia Group forecasts the average growth of TPE for 2006-2011 at 6.3% reaching about 4 mln tons by 2011. Automotive is the largest application of TPEs accounting for 40-50%. Value gains will expand an even stronger 7.8% pa to US$13.7 bln over the same period, due to the increasing number of applications that require costlier types of TPEs and sustained high energy prices that will raise TPE production costs. China will expand its share of the world market from 31% in 2006 to 35% in 2011, although the US will remain the world's largest manufacturer of some products such as olefinic based TPEs.

In developed economies most of the easy substitutions for thermoset rubber have been completed and demand is slowing. There are signs of commoditization in areas like consumer and building/construction, and the overall market is shifting primarily to China , where many products made of TPEs are now being manufactured. These include footwear, house ware, consumer products, appliances, tools and sports/leisure products. TPE suppliers are responding with higher-performing materials and extended functionality. Today, TPE finds application on the higher rungs of the performance ladder.
SEBS has joined thermoplastic polyolefins (TPOs) in replacing copolyester elastomer (COPE) TPEs in more highly engineered applications like airbag covers. Similarly, styrenic TPEs are increasingly being used to replace more costly TPUs in abrasion-resistant applications. Specialty TPE grades are emerging with greater transparency, lower hardness, chemical resistance, and scratch and mar resistance. The �greening� of plastics is also having an impact with possibility of bio based or renewable-content materials. Higher-heat materials are also being developed for very small and tightly packaged applications in wire and cable and automotive. Overmold bondability to other thermoplastics, textiles and metals remains a focus of R&D. Regulatory and market demands are also forcing suppliers to develop new materials without halogenated flame retardants and with lower volatile emissions to prevent fogging in.

At K 2007, Arkema introduced first commercial engineering TPE made from renewable resources. Pebax Rnew is a polyether-block-amide (PEBA) made with Arkema's Rilsan nylon 11, based on castor oil. Grades have 20-90% renewable content and Shore hardness from 25 D to 72 D for electronics, athletic shoes, and automotive uses.
Spain 's Merquinsa introduced the world's first TPUs derived from bio based materials such as vegetable or fatty acid based polyols. A biobased TPU from GLS, called OnFlex U, comes from soybean oils. Renewable content is claimed to be 30-45% and hardness ranges from 65 to 95 Shore A. Performance is similar to traditional grades for sectors like medical, consumer, and industrial. New materials include bio-based materials with 10-100% renewable content. The nylon 12-based materials, based on castor and canola oil, have properties similar to standard grades and are targeted for sport goods.
Multibas has introduced new Multiflex TEA alloys that provide improved bondability to engineering thermoplastics. The company is developing improved weathering grades (withstanding up to 4000 kJ accelerated exposure) for auto exterior uses. For interior applications, the company is focused on new grades that provide fogging resistance at up to 110 C/230 F, suntan-oil resistance, and improved gas-fading resistance.

Transparent TPEs are in greater demand for enhanced design flexibility in a range of overmolding applications, Kryberg has launched new Thermolast K grades of translucent SEBS-based TPEs that boast a previously unattainable level of adhesion to PC and ABS. They also bond to other styrenics, PBT, acrylic, and PETG. Hardnesses are 50 A to 80 A. Heat resistance has been extended with new Thermolast V SEBS compounds that have a service temperature of 140 degree C for industrial and auto under hood parts.
Teknor's new Elexar EL1402 family of non-halogenated SEBS grades meet UL 94V-0 with hardness starting at 50 A for wire/cable and molding. New value-added SEBS grades include Monprene MP1871R to replace silicone in medical tubing and MP2295 Kuraray has built a pilot plant in Japan for an entirely new all-acrylic TPE. It consists of alternating hard blocks of PMMA and soft blocks of poly-n-butyl-acrylate. It is said to offer weatherability, transparency, softness, and good adhesion to polar resins and paint. Hardness is 30 Shore A to 60 D. It can be injection molded, slush molded, and extruded into sheet and film. Sony has used it in camera grips. Other markets are consumer and sporting goods, automotive, and optical films.
New TPE alloys are finding a place in auto interiors. A Schulman introduced a licensed technology for Inteva Products (formerly Delphi Interiors & Closures), which consists of a hybrid TPE for slush molding IP skins to replace slush-molded TPU or sprayed urethane. The styrenic/olefinic alloy has lower density than TPU and is reportedly comparable in scratch and abrasion resistance and weatherability. Kuraray has built a pilot plant in Japan for an entirely new all-acrylic TPE. It consists of alternating hard blocks of PMMA and soft blocks of poly-n-butyl-acrylate. It is said to offer weatherability, transparency, softness, and good adhesion to polar resins and paint. Hardness is 30 Shore A to 60 D. It can be injection molded, slush molded, and extruded into sheet and film. Sony has used it in camera grips. Other markets are consumer and sporting goods, automotive, and optical films.