18 January 2024 | Eduardo Henrique Backes, Samarah Vargas Harb, Leonardo Alves Pinto, Nayara Koba de Moura, Guilherme Ferreira de Melo Morgado, Juliano Marini, Fabio Roberto Passador, and Luiz Antonio Pessan
Thermoplastic polyurethanes (TPUs) have gained significant attention due to their versatile chemistry and wide range of fabrication techniques, enabling diverse applications. TPUs are composed of soft and hard segments, which can be tailored to achieve specific properties such as soft touch, elasticity, transparency, impact strength, chemical resistance, and elastic memory. While petroleum-based precursors are still widely used, green sources of diisocyanates, polyols, and chain extenders are increasingly being explored. This review discusses the fundamental chemistry, synthesis, fabrication techniques, and structure of TPUs, as well as their blends and composites. TPUs are classified as thermoplastic elastomers (TPEs) and can be combined with other polymers or additives to enhance their properties for specific applications. The processability of TPUs allows for various fabrication techniques, including melt mixing, additive manufacturing, injection molding, and extrusion. Non-melt-based methods such as electrospinning, thermally induced phase separation, and salt leaching are also applicable. The versatility of TPUs has led to their use in biomedical, agricultural, textile, electronic, aerospace, food packaging, and construction fields. TPUs can be blended or combined with other materials to improve mechanical, thermal, and functional properties. The ability to reuse and biodegrade TPUs reduces waste and expands their applicability. The synthesis of TPUs involves three main components: diisocyanates, polyols, and chain extenders. Diisocyanates can be aliphatic or aromatic, with aliphatic ones offering better light stability. Polyols can be polyester, polyether, or polycarbonate-based, each with distinct properties. Chain extenders are low molecular weight diols that help reduce microphase separation and increase molecular weight. The reaction between diisocyanates and polyols or chain extenders forms the urethane group, leading to the formation of TPUs with tailored properties.Thermoplastic polyurethanes (TPUs) have gained significant attention due to their versatile chemistry and wide range of fabrication techniques, enabling diverse applications. TPUs are composed of soft and hard segments, which can be tailored to achieve specific properties such as soft touch, elasticity, transparency, impact strength, chemical resistance, and elastic memory. While petroleum-based precursors are still widely used, green sources of diisocyanates, polyols, and chain extenders are increasingly being explored. This review discusses the fundamental chemistry, synthesis, fabrication techniques, and structure of TPUs, as well as their blends and composites. TPUs are classified as thermoplastic elastomers (TPEs) and can be combined with other polymers or additives to enhance their properties for specific applications. The processability of TPUs allows for various fabrication techniques, including melt mixing, additive manufacturing, injection molding, and extrusion. Non-melt-based methods such as electrospinning, thermally induced phase separation, and salt leaching are also applicable. The versatility of TPUs has led to their use in biomedical, agricultural, textile, electronic, aerospace, food packaging, and construction fields. TPUs can be blended or combined with other materials to improve mechanical, thermal, and functional properties. The ability to reuse and biodegrade TPUs reduces waste and expands their applicability. The synthesis of TPUs involves three main components: diisocyanates, polyols, and chain extenders. Diisocyanates can be aliphatic or aromatic, with aliphatic ones offering better light stability. Polyols can be polyester, polyether, or polycarbonate-based, each with distinct properties. Chain extenders are low molecular weight diols that help reduce microphase separation and increase molecular weight. The reaction between diisocyanates and polyols or chain extenders forms the urethane group, leading to the formation of TPUs with tailored properties.