ETFE Tefzel: Properties, Uses & Cost Guide
Tensile data verified against MatWeb.com database & manufacturer datasheets · Last updated July 2026
Published: 2026-05-30
Ethylene tetrafluoroethylene (ETFE), best known by Chemours' trade name Tefzel, is a partially fluorinated copolymer of ethylene and tetrafluoroethylene that occupies a unique position in the fluoropolymer family: it offers approximately 2× the...
Ethylene tetrafluoroethylene (ETFE), best known by Chemours' trade name Tefzel, is a partially fluorinated copolymer of ethylene and tetrafluoroethylene that occupies a unique position in the fluoropolymer family: it offers approximately 2× the tensile strength (45 MPa) and significantly higher impact resistance than fully fluorinated PTFE or PFA, while retaining excellent chemical resistance (superior to most non-fluorinated polymers, though not as universal as PTFE/PFA). The ethylene comonomer introduces hydrogen atoms into the otherwise fully fluorinated backbone, breaking up the crystallinity and providing a tougher, lighter, and more processable material at the tradeoff of reduced upper service temperature (150°C vs 260°C for PTFE/PFA) and slightly reduced chemical resistance.
ETFE is most famous for its architectural application as transparent membrane roofing—the Eden Project biomes in the UK, the Beijing National Aquatics Center (Water Cube), and Allianz Arena in Munich all use ETFE film cushions. In industrial applications, ETFE is widely used for rotomolded chemical storage tanks, wire and cable jacketing for aerospace (high strength-to-weight, radiation crosslinkable for improved temperature rating), and chemical process vessel linings. ETFE can be processed by conventional injection molding, extrusion, and rotomolding at melt temperatures of 290-340°C. Unlike PTFE, ETFE can be radiation crosslinked to improve its high-temperature creep resistance and abrasion resistance—crosslinked ETFE wire insulation is the standard for aerospace hookup wire (MIL-W-22759 specification).
Recommended Applications
ETFE Tefzel is commonly specified for:
⚠ Not Recommended For
ETFE Tefzel is not recommended for:
- Applications requiring ultra-low friction coefficient (ETFE friction ~0.4 vs PTFE ~0.05; use PTFE for bearings)
- Continuous service above 150°C (use PFA or PEEK for higher temperature)
- Strong polar solvent exposure at elevated temperature (use PTFE or PFA for aggressive chemical environments)
Selection & Application Guide
ETFE (Tefzel) is the high-strength fluoropolymer choice for wire and cable insulation, architectural membranes, and chemical lining applications where PTFE's mechanical weakness is a problem. Choose ETFE over PTFE when tensile strength (45 MPa vs 25 MPa) and abrasion resistance are needed; over PFA when lower cost and higher mechanical toughness matter and the 150°C service temperature is sufficient. ETFE is also the most radiation-resistant fluoropolymer.
Real-World Applications
ETFE's combination of electrical properties, flame resistance (limiting oxygen index 31%), and mechanical toughness makes it standard for MIL-W-22759 aircraft wiring.
ETFE film is used for iconic building facades (Beijing Water Cube, Eden Project) providing 95% light transmission, self-cleaning, and 30+ year weathering resistance.
ETFE film provides UV-resistant, high-transmission front sheets for flexible and building-integrated photovoltaic modules.
ETFE lining provides chemical resistance similar to PTFE with better mechanical strength and weldability for tank and vessel lining in chemical processing.
Processing & Cost Considerations
Manufacturing Tips
- ETFE processes at 270-310°C melt temperature with mold temperatures of 80-120°C — lower than PFA and achievable on standard high-temperature injection molding machines.
- ETFE can be extruded into film (down to 12μm thickness), wire coating, and tubing. It has a relatively narrow processing window compared to commodity plastics — precise temperature control is important.
- ETFE is the most radiation-resistant fluoropolymer, maintaining properties after gamma and electron-beam sterilization. This makes it suitable for nuclear and space applications where other fluoropolymers degrade.
ETFE costs $30-60/kg — more than commodity plastics but less than PFA ($50-100/kg) and much less than PEEK. For wire insulation, ETFE provides the best balance of performance and cost among fluoropolymers. ETFE architectural film is expensive per square meter but offers 30+ year service life with minimal maintenance, reducing total lifecycle cost compared to glass or metal facades.
Technical Properties
| Density | 1.70 g/cm³ |
|---|---|
| Tensile Strength | 45 MPa |
| Melting Point | 260 °C |
| Shrinkage Rate | 2.0-3.0% |
| Flexural Modulus | 1.2 GPa |
| Hdt | 75 °C at 1.82 MPa |
| Continuous Service Temp | 150 °C |
Engineering Tool: Shrinkage & Cost Estimator
Calculate part weight, mold cavity dimensions accounting for shrinkage, and material cost — all locally in your browser.
Equivalents & Cross-References
| Equivalent / Alternate | Action |
|---|---|
| Chemours Tefzel | |
| Dyneon ETFE | |
| Daikin Neoflon ETFE |
Frequently Asked Questions
What are the practical differences between ETFE and PTFE for wire and cable insulation?
ETFE dominates aerospace and mass-transit wire insulation for three reasons: (1) Mechanical toughness—ETFE's tensile strength (45 MPa) is approximately 2× PTFE's (25 MPa) and its abrasion resistance is far superior, critical for wire bundles subject to vibration. (2) Weight—ETFE's density (1.70 g/cm³) is 23% lower than PTFE (2.20 g/cm³), saving kilograms on aircraft wiring harnesses. (3) Radiation crosslinking—ETFE can be crosslinked via electron beam irradiation, raising its continuous service temperature from 150°C to 200°C and dramatically improving cut-through resistance. PTFE cannot be crosslinked—it chain-scissions (degrades) under radiation. PTFE is still preferred for high-frequency (RF/microwave) coaxial cables where its lower dielectric constant (2.1 vs 2.6 for ETFE) and lower dissipation factor (0.0002 vs 0.005) matter.
How does ETFE compare to PTFE for wire insulation?
ETFE has 2× higher tensile strength (45 MPa vs 25 MPa), better abrasion resistance, and can be extruded as wire insulation (PTFE requires paste extrusion and sintering). PTFE offers better chemical resistance and higher temperature rating (260°C vs 150°C for ETFE). For aerospace wiring below 150°C, ETFE is standard; for extreme temperature or chemical environments, PTFE is specified.
Can ETFE be welded?
Yes. ETFE can be heat-welded, extrusion-welded, and impulse-welded — a significant advantage over PTFE which cannot be welded. This makes ETFE ideal for tank lining systems and architectural membrane seams where weldable joints are required.
Is ETFE suitable for outdoor applications?
Yes. ETFE has outstanding UV and weather resistance with minimal property degradation over 30+ years of outdoor exposure. It does not yellow or become brittle like many transparent polymers. ETFE film maintains >90% light transmission after decades of outdoor service.
What is the difference between ETFE and FEP?
ETFE has higher mechanical strength (45 MPa vs 30 MPa tensile), better abrasion resistance, and better radiation resistance. FEP has better chemical resistance (fully fluorinated), lower coefficient of friction, and higher maximum service temperature (200°C vs 150°C). Choose ETFE for mechanical/wear applications; FEP for chemical/temperature applications.
Is ETFE recyclable?
Yes. ETFE is thermoplastic and can be melted and reprocessed multiple times without significant property degradation. This is an environmental advantage over thermoset materials. ETFE architectural membranes can be recycled at end of life, contributing to sustainable building certifications.
Related Diagnostics & Materials
PEEK Polyetheretherketone: High-Performance Polymer...
Polyetheretherketone (PEEK) is a colorless organic thermoplastic polymer in the polyaryletherketone (PAEK) family,...
Ultem PEI (Polyetherimide): High-Temperature Amorphous...
Polyetherimide (PEI), best known by Sabic's trade name Ultem, is an amorphous high-performance thermoplastic...
PTFE Teflon: Ultimate Chemical Resistance & Low-Friction...
Polytetrafluoroethylene (PTFE), widely known by the trade name Teflon, is a fluoropolymer with the lowest...
PPS Ryton: Polyphenylene Sulfide High-Temp...
Polyphenylene sulfide (PPS), best known by Solvay's trade name Ryton, is a semicrystalline high-performance...
LCP Vectra: Liquid Crystal Polymer for Micro-Molding &...
Liquid Crystal Polymer (LCP), best known by Celanese's trade name Vectra, is a unique class of thermotropic...
Vespel Polyimide: Extreme-Temperature Polymer for...
Polyimide (PI), commercially known as DuPont Vespel, is the highest-temperature-rated polymer commercially...
PAI Torlon: Polyamide-Imide Extreme-Performance Polymer...
Polyamide-imide (PAI), commercially known as Solvay Torlon, occupies the performance space between PEEK and...
PES Veradel: Polyethersulfone Transparent High-Temp...
Polyethersulfone (PES), commercially known as Solvay Veradel or BASF Ultrason E, is an amorphous high-temperature...
References & Industry Standards
- ASTM International. Standard Specifications for Engineering Plastics & Thermoplastics. astm.org
- UL Prospector. Plastics & Elastomers Material Database. ulprospector.com
- MatWeb. Material Property Data for Engineering Thermoplastics. matweb.com
- ISO 1043. Plastics — Symbols and Abbreviated Terms. iso.org