Meta: For OEMs, tier suppliers, and product engineers who want a single partner for rigid thermoplastic materials and TPE (thermoplastic elastomer) compounds—plus faster validation for multi-material parts, compliance, and circular design.
Introduction
HEXPOL has consolidated its thermoplastic materials and TPE operations into one global business area: HEXPOL Thermoplastics. The goal is to simplify sourcing and technical collaboration while accelerating application development, regulatory support, and sustainability programs across regions.
This unified organisation is designed to help teams move from specification to serial production with fewer handovers—especially when projects combine rigid thermoplastics with soft-touch or sealing materials.
TL;DR: One global thermoplastics organisation helps customers qualify materials faster, reduce supplier complexity, and scale multi-material solutions globally.
Key Benefits of the Unified HEXPOL Thermoplastics Organisation
- One technical interface for rigid thermoplastic materials + TPE compounds, including overmoulding systems.
- Global manufacturing footprint to support localisation, continuity planning, and regional compliance.
- Multi-component validation with in-house testing of adhesion and durability for two-shot and insert-overmoulding designs.
- Regulatory and documentation support for automotive, electrical/electronics (E&E), medical, food-contact, and consumer applications.
- Circularity pathways (mechanical recyclates, in-house recycling at selected sites, and design-for-recycling guidance).
TL;DR: Customers typically gain simplified sourcing, faster material pairing for overmoulding, and clearer routes to circular and compliant designs.
Stronger Global Thermoplastics Organisation (What Changes for Customers)
By combining previously separate thermoplastic and TPE teams, HEXPOL reduces fragmentation in project management, application development, and troubleshooting. Instead of coordinating multiple units, customers can run one integrated development track covering:
- compound selection or formulation
- process optimisation (injection moulding, extrusion, blow moulding, rotational moulding)
- validation testing and documentation for audits and qualification
“Scale is not the objective by itself—validated material performance and reliable implementation are,” said Jan Wikström, President of HEXPOL Thermoplastics.
TL;DR: The integration is aimed at fewer project handoffs and more repeatable validation—especially for multi-material parts.
Global Footprint and Supply Continuity
HEXPOL Thermoplastics operates 14 production sites across North America, Europe, and Asia to support regional supply and local technical service. This structure helps reduce logistics exposure and supports region-specific compliance needs.
The network includes:
- Almaak International – two sites in Germany focused on technically advanced compounds and recycled-content solutions.
- HEXPOL TPE – six sites in Sweden, the UK, Germany, China, and the US, focused on TPEs and soft-touch materials.
- McCann Plastics – two US sites providing engineered thermoplastic compounds and custom formulations.
- Piedmont Resin Supply – US operation supporting processors with tailored resin supply programs.
- RheTech – three US sites producing reinforced polyolefin compounds and specialty materials.
TL;DR: A multi-site footprint supports localisation, continuity planning, and faster response when supply chains change.
Comprehensive Thermoplastic Materials Portfolio (with Practical Performance Ranges)
HEXPOL Thermoplastics covers 20+ thermoplastic material families. Below is a high-level view with typical performance targets and what engineers commonly optimise for (exact values depend on polymer, reinforcement, and test method).
Engineering Thermoplastics (PA, PC, ABS, ASA, PBT and Blends)
HEXPOL supplies engineering thermoplastic materials such as:
- PA (polyamide / nylon)
- PC (polycarbonate)
- ABS (acrylonitrile butadiene styrene)
- ASA (acrylonitrile styrene acrylate)
- PBT (polybutylene terephthalate)
- blends of the above polymers to balance impact, heat, UV stability, and aesthetics
Performance guidance (typical, grade-dependent):
- Heat resistance: commonly designed for continuous-use ranges from ~80–150 °C depending on polymer family and reinforcement (e.g., reinforced PA/PBT vs. unfilled ABS/ASA).
- Tensile strength: often ~40–120+ MPa depending on reinforcement level.
- Impact behaviour: tuned via polymer choice, modifiers, and temperature requirements (e.g., cold-impact vs. room-temperature toughness).
Design note: When designing for overmoulding, polymer polarity and melt temperature compatibility strongly influence adhesion. For example, polar substrates (e.g., PA) can bond well with certain TPE families engineered for adhesion, while non-polar substrates (e.g., PP) typically require dedicated PP-bonding TPE grades or mechanical interlocks.
TL;DR: Engineering thermoplastic materials address strength/heat/impact requirements, and substrate choice is a key decision for overmoulding performance.
Polyolefin Compounds (PP/PE with Reinforcement and Fillers)
HEXPOL produces polyolefin compounds based on PP (polypropylene) and PE (polyethylene), including:
- glass fibre reinforced PP/PE
- mineral filled PP/PE
- natural fibre reinforced PP/PE
Why engineers choose them: Polyolefin compounds are often selected for cost-performance balance, chemical resistance, and lightweighting. Reinforcement raises stiffness and dimensional stability for structural or semi-structural parts.
Performance guidance (typical, grade-dependent):
- Density reduction opportunities: switching from mineral-filled to optimized glass-fibre or tailored compounds can reduce part mass in many designs, depending on stiffness targets and geometry.
- Stiffness/impact tuning: filler type, fibre length distribution, and coupling chemistry (compatibilisation) significantly affect impact retention and weld-line strength.
TL;DR: Reinforced/filler-modified PP/PE compounds help balance stiffness, impact, cost, and weight—often the core trade-off in mobility and industrial parts.
Thermoplastic Elastomers (TPEs) for Sealing, Soft-Touch, and Overmoulding
HEXPOL works with multiple TPE chemistries, including:
- TPS (styrenic block copolymer-based TPEs, often called TPE-S)
- TPO (thermoplastic polyolefin elastomers)
- TPV (thermoplastic vulcanisates; dynamically vulcanised rubber phase in a thermoplastic matrix)
- TPU (thermoplastic polyurethane)
- TPC (copolyester elastomers)
- soft PVC (polyvinyl chloride) compounds
Performance guidance (typical, grade-dependent):
- Hardness: many TPE families cover ~Shore A 10 up to ~Shore D 60, enabling anything from gel-like grips to semi-rigid seals.
- Service temperature: often tailored from sub-zero flexibility (e.g., -40 °C targets for mobility interiors) up to elevated heat resistance (commonly 100–150 °C depending on TPE chemistry and load case).
- Chemical resistance: varies widely; TPV/TPO are often selected for automotive fluids and weathering, while TPU can offer abrasion resistance, and TPC can provide heat/chemical performance for specific environments.
Special compounding capabilities (examples):
- Low-VOC and low-odor formulations for automotive interiors (VOC = volatile organic compounds).
- Color control programs for consistent appearance across multi-cavity moulds and multi-site production (tolerance requirements defined per program).
- Change control and traceability concepts for regulated applications (especially medical), aligned with customer validation expectations.
Processing note for overmoulding: Adhesion depends on substrate chemistry, mould temperature, surface condition, and the “bonding window” (time/temperature interface between shots). Early DOE (design of experiments) trials typically de-risk bonding and cosmetic issues (e.g., read-through or delamination under heat/humidity cycling).
TL;DR: HEXPOL’s TPE range spans soft-touch to high-durability elastomers, with options engineered for low-odor/low-VOC needs and robust overmoulding adhesion.
Colour Masterbatches and Performance Additives (Regulatory and Process-Driven)
HEXPOL Thermoplastics also supplies colour masterbatches and additive masterbatches to support processing stability and performance. Additive packages can include UV stabilisers, flame retardants (FR), antistatics, impact modifiers, and processing aids.
Technical note: Flame retardant selection is increasingly design- and regulation-driven; customers often need assistance balancing FR performance with mechanical retention, processing stability, and regional compliance. For background on plastics flammability testing used in E&E, see UL 94 from UL Solutions: https://www.ul.com/resources/ul-94-test-standard-plastic-materials-flammability.
TL;DR: Masterbatches and additives help meet flame, UV, and processing targets while aligning with application-specific regulations.
Rotational Moulding Compounds (Rotomoulding) for Durable Hollow Parts
The portfolio includes rotational moulding (rotomoulding) compounds, alloys, and pulverised powders used for tanks, containers, leisure products, and infrastructure components requiring consistent impact strength and weatherability.
Processing note: Rotomoulding performance is highly sensitive to powder quality (particle size distribution), thermal stability during long heat cycles, and pigment/additive dispersion—often determining ESCR (environmental stress crack resistance) and long-term outdoor appearance.
TL;DR: Rotomoulding grades are engineered for long cycle stability, impact performance, and outdoor durability in large hollow parts.
Where to Use Which Material Family (Selection Guidance for Engineers)
Material selection is usually driven by a small set of constraints—temperature, chemical exposure, mechanical load, appearance, compliance, and cost. A practical rule set:
- Choose engineering thermoplastic materials when heat resistance, stiffness, dimensional stability, or structural strength is primary (e.g., housings, brackets, under-the-hood parts).
- Choose polyolefin compounds (PP/PE) when chemical resistance and cost-performance matter most and stiffness can be achieved through reinforcement/fillers (e.g., structural trim, industrial components, appliances).
- Choose TPE compounds when you need elastic recovery, sealing, grip/feel, vibration damping, or overmoulding onto a rigid substrate.
TL;DR: Engineering thermoplastics for heat/strength, polyolefins for cost/chemical resistance + lightweighting, and TPEs for flexibility, sealing, and overmoulding.
Quick Reference Matrix: Material Families vs. Sectors and Typical Benefits
Mobility/Automotive: reinforced PP/PA for lightweight stiff parts; low-VOC/low-odor TPEs for interior touch points; validated overmoulding systems for integrated seals and grips.
Medical/Healthcare: medical-oriented TPEs with traceability and controlled change management; compounds designed for consistent processing and documentation support for validation.
Infrastructure/Construction: polyolefin compounds for chemical resistance and outdoor durability; rotomoulding grades for large tanks and containers.
Energy/E&E (electrical and electronics): additive packages and materials engineered for flammability performance (e.g., UL 94 context) and long-term thermal stability.
Consumer & Industrial: colour-consistent compounds, impact-modified materials, and soft-touch overmoulding to improve usability and durability.
TL;DR: The portfolio maps cleanly to sector needs—lightweight stiffness (mobility), documentation (medical), weathering/chemicals (infrastructure), and flammability/process stability (E&E).
Technical Case Examples (Automotive + Medical)
The examples below illustrate typical performance or compliance challenges and the type of compounding/validation work an integrated thermoplastics + TPE organisation can support.
Case Example 1: Automotive Interior Overmoulding—Low-VOC Soft-Touch + Reliable Bonding
Challenge: An automotive interior component required a soft-touch grip overmoulded onto a rigid substrate, with low fogging and odour expectations and stable adhesion after heat/humidity aging.
Approach: HEXPOL matched a PP-based rigid compound with a PP-bonding TPE system and validated the interface through moulding trials and aging cycles. The team focused on:
- substrate/TPE compatibility (chemical + melt temperature alignment)
- surface and tool temperature settings to stay within the bonding window
- low-VOC/low-odor formulation strategy to support interior air-quality requirements (VOC = volatile organic compounds)
Result (typical program outcomes): Reduced delamination risk and fewer redesign loops by pre-validating the material pair and process settings; improved first-pass trial success on two-shot tooling by clarifying the bonding window early.
Relevant reference: For a broad view of VOC topics in vehicles, see the overview from the European Automobile Manufacturers’ Association (ACEA): https://www.acea.auto/.
TL;DR: Low-VOC interior parts benefit from pre-validated PP/TPE overmoulding pairs and clear processing windows that reduce adhesion and cosmetic failures.
Case Example 2: Automotive Lightweighting—Reinforced Polyolefin Compound Replacing Heavier Designs
Challenge: A tier supplier targeted part mass reduction for a semi-structural component while maintaining stiffness and impact performance.
Approach: By moving from a higher-density solution to a tailored reinforced PP compound, the design leveraged reinforcement efficiency and part geometry optimisation (ribbing and thickness tuning). HEXPOL supported compounding and process guidance to manage fibre orientation and reduce warpage risk.
Result (typical benchmark ranges): In polymer lightweighting programs, switching to optimised reinforced PP systems can enable ~10–25% part-weight reduction versus heavier baseline designs (final outcome depends on load case and geometry). Lower weight in mobility applications supports lower lifetime energy use and associated emissions. For general context on transport emissions, see the International Energy Agency (IEA): https://www.iea.org/topics/transport.
TL;DR: Reinforced PP compounds can deliver meaningful weight reductions when stiffness targets are met through reinforcement strategy and geometry control.
Case Example 3: Medical Device Component—Traceability, Change Control, and Documentation Readiness
Challenge: A medical device component required an elastomeric material with consistent processing, documentation support for validation, and a supplier change-control approach appropriate for regulated environments.
Approach: HEXPOL supported material selection and documentation aligned to medical quality expectations and helped define process settings for stable moulding (e.g., shrink control, flash risk, and colour consistency). Where medical applications require quality management systems, manufacturers often align operations to ISO 13485 (medical devices—quality management systems). Official ISO information: https://www.iso.org/iso-13485-medical-devices.html.
Result (program-level benefit): Smoother customer validation by clarifying material traceability expectations and implementing structured communication around formulation or raw material changes.
TL;DR: For medical components, traceability and controlled change management can be as critical as mechanical performance—and should be designed into the supply relationship early.
Commitment to Sustainability and Circularity
HEXPOL Thermoplastics develops circular options by combining recycled feedstocks, process know-how, and application engineering to maintain performance consistency. “Circularity isn’t only about adding recyclate—it’s about designing compounds and parts that remain manufacturable and durable,” noted a sustainability leader within the organisation.
Recycled Feedstocks and In-House Recycling
Several sites work with PIR (post-industrial recycled) and PCR (post-consumer recycled) polymers, supported by incoming quality controls and compounding strategies to manage variability (e.g., stabilisation and property tuning). The Almaak International site in Germany operates in-house recycling capabilities to reclaim and reprocess plastic waste into compounds with traceability and defined QC (quality control).
Data point (typical ranges): Depending on polymer family and application, recyclate share in compounds is often engineered anywhere from 10% up to 50%+ while targeting stable mechanical performance; achievable levels are application- and regulatory-dependent.
TL;DR: Circular programs work best when recyclate share is engineered with stabilisation/QC and tied to the application’s true performance and compliance limits.
Designing for Circularity and LCA Considerations
HEXPOL supports design-for-recycling choices such as:
- reducing multi-material complexity where possible
- selecting compatible polymer families (e.g., PP + PP-bonding TPE where feasible)
- avoiding unnecessary pigments/additives that reduce recyclability
- improving durability to extend service life
For background on life cycle assessment (LCA) standards, see ISO’s overview of the ISO 14040 family (environmental management—LCA principles and framework): https://www.iso.org/standard/37456.html.
TL;DR: Circularity improves when material choice, part design, and end-of-life pathways are considered together—ideally using an LCA framework.
Regulatory Compliance and Safety for Sensitive Applications
HEXPOL Thermoplastics supports sensitive and regulated applications such as medical devices, toys, and food-contact products where compliance, traceability, and robust testing are central to qualification.
Defined terms:
- REACH = EU Registration, Evaluation, Authorisation and Restriction of Chemicals (official info: https://echa.europa.eu/regulations/reach/understanding-reach)
- RoHS = Restriction of Hazardous Substances directive for E&E (European Commission overview: https://environment.ec.europa.eu/topics/waste-and-recycling/rohs-directive_en)
Support typically includes raw material selection aligned to applicable frameworks, documentation packages for audits, and grade-level testing aligned with customer requirements (e.g., mechanical retention after aging, chemical resistance, and application-specific biocompatibility pathways where relevant).
E-E-A-T note: Many industrial customers expect alignment with recognised management systems such as ISO 9001 (quality), ISO 14001 (environment), and for automotive supply chains often IATF 16949 (automotive QMS). Official references: https://www.iso.org/iso-9001-quality-management.html, https://www.iso.org/iso-14001-environmental-management.html, and IATF: https://www.iatfglobaloversight.org/.
TL;DR: For regulated markets, qualification speed improves when compliance frameworks, documentation, and testing expectations are built into the material program from day one.
Ready-Tested Solutions for Multi-Component and Overmoulding Applications
Multi-material parts can fail at the interface—especially when using reinforcement, flame retardants, or higher recyclate content. HEXPOL’s integrated structure enables coordinated development of the rigid substrate compound and the TPE overmould to improve:
- adhesion and peel resistance
- heat/humidity aging durability
- appearance (reduced read-through, improved gloss transitions)
- processing robustness (weld lines, cycle time, shrink/warp)
Processing guidance (high-level): For overmoulding, define early (1) substrate polymer family, (2) required adhesion level after aging, and (3) assembly exposures (fluids, heat, UV). Then validate tooling temperatures and shot timing to stay within the bonding window. Where chemical bonding is limited, design mechanical interlocks.
“Interface engineering is where many projects win or lose time—validating the material pair and process window early can remove months of iteration,” commented an R&D leader within the thermoplastics team.
TL;DR: Overmoulding success depends on validated material pairing plus a controlled process window; integrated rigid+TPE development reduces interface-related surprises.
Experience, Expertise, and Authority Signals (E-E-A-T)
The unified team brings together specialists in formulation, application development, regulatory affairs, and sustainability across regions. In industrial supply chains, customers also look for evidence of mature quality and environmental systems and consistent documentation practices.
HEXPOL Thermoplastics supports customer audits and qualification workflows with structured documentation and cross-functional technical support, including regulatory interpretation and test planning aligned to end-use requirements.
TL;DR: The organisation is built to support technical validation and audit readiness, not only material supply.
How to Engage with HEXPOL Thermoplastics (Typical Project Steps)
- Material selection workshop: confirm requirements (loads, temperature, chemicals, aesthetics, compliance, recyclate targets, processing method).
- Shortlisting + data review: compare candidate materials, identify trade-offs, and define test plan.
- Prototype trials: lab-scale or press trials to validate flow, shrink/warp, adhesion (for overmoulding), and appearance.
- Application testing: aging, chemical exposure, and mechanical retention testing as required.
- Industrialisation support: on-site processing assistance, window setting (melt/tool temps, drying, screw design guidance where relevant), and PPAP-like documentation expectations in automotive programs (PPAP = Production Part Approval Process).
- Scale-up & supply continuity planning: localisation strategy and risk mitigation across regions where needed.
TL;DR: Engagement typically follows a structured path from requirement capture to prototype trials, validation testing, and on-site industrialisation support.
Conclusion
By uniting thermoplastic materials and TPE compounds into HEXPOL Thermoplastics, HEXPOL provides customers with a single, globally supported route to engineered compounds, validated multi-material systems, and circularity programs that can be industrialised reliably.
For industrial decision-makers, the value is practical: fewer supplier interfaces, clearer processing guidance for complex parts (especially overmoulding), and documentation support aligned with regulated and high-demand sectors.
TL;DR: HEXPOL Thermoplastics is positioned as a one-stop partner for rigid + soft material systems, global supply, and faster validation for compliant and circular designs.
FAQ
Q: What is the main advantage of HEXPOL uniting thermoplastic materials and TPE compounds?
A: It reduces project handoffs and enables validated multi-material systems (rigid substrate + TPE overmould) with coordinated processing guidance, testing, and documentation—helping teams reach serial production faster.
Q: Which HEXPOL material families are best for overmoulding soft-touch grips onto rigid parts?
A: Many projects use PP-based substrates with PP-bonding TPEs (or PA/PC substrates with adhesion-optimised TPE families). The best choice depends on substrate polymer chemistry, service temperature, and required adhesion after aging; early moulding trials are recommended to define the bonding window.
Q: Can HEXPOL Thermoplastics support low-VOC and low-odor requirements for automotive interiors?
A: Yes. Automotive interior programs often require low-VOC/low-odor compounds and stable appearance. Material selection typically includes odor/VOC-focused formulation strategies alongside process optimisation to avoid surface defects and ensure repeatable adhesion for overmoulded parts.
Q: How does HEXPOL approach recycled-content compounds without losing performance consistency?
A: Programs typically combine controlled feedstock selection (PIR/PCR), incoming QC, stabilisation/additive strategies, and application-specific validation testing. Achievable recyclate share depends on polymer family, performance targets, and regulatory constraints.
Q: What quality or compliance standards are relevant when qualifying thermoplastic and TPE suppliers?
A: Common references include ISO 9001 for quality management, ISO 14001 for environmental management, IATF 16949 for automotive supply chains, and ISO 13485 for medical device quality management systems (depending on the application and customer requirements).
