Film Lamination Guide: TPU, PU and PE Differences and Applications
Film choice defines lamination quality. This guide clarifies the technical differences, temperature ranges and target products for TPU, PU and PE films.
Film lamination is the industrial method for giving fabric water resistance, breathability, a smoother hand feel or a decorative surface. The three main film classes — TPU, PU and PE — require different temperature, pressure and application ranges. The right film choice depends directly on the end-use requirement and on your cost calculation.
TPU Film (Thermoplastic Polyurethane)
TPU film is the gold standard in outdoor and performance textiles. Waterproof but breathable; abrasion-resistant and UV-tolerant. Typical application temperature is 160–180 °C; use cases include rainwear, softshell jackets, trekking pants, tents and backpack fabric. Works in 80–200 micron thickness. TPU is noticeably more expensive than single-use PE, but the comfort and wash-durability delivered are on a different level.
PU Film (Polyurethane)
PU film is softer and more flexible — preferred where direct skin contact matters. Laminates in the 140–160 °C range. Underwear (bra, leggings), medical products (protective wear, orthopaedic support), and baby / kids products are the core use cases. Thin 60–150 micron construction protects without sacrificing flex and drape.
PE Film (Polyethylene)
PE film is the lowest-cost option and wins in disposable applications. Laminates at a low 120–140 °C — meaning energy savings and shorter cycle time. Single-use surgical gowns, mask fabric, hospital sheets and short-life agricultural covers are PE's natural fit. The right choice for cost-driven production where durability or breathability are not expected.
TPU vs PU vs PE — Quick Comparison
| Film | Temperature | Typical Thickness | Main Application |
|---|---|---|---|
| TPU | 160–180 °C | 80–200 µm | Outdoor apparel, softshell, tents |
| PU | 140–160 °C | 60–150 µm | Underwear, medical, baby products |
| PE | 120–140 °C | 30–100 µm | Single-use, protective |
All three film types can run on the same machine. The Mearic ML series adds front feed and rear external rewind modules to the roll-to-roll sublimation architecture, supporting TPU, PU and PE lamination as well as roll-fabric sublimation printing. One machine, two jobs: lamination one shift, sublimation the next. See the Mearic ML series page for technical specifications.