TPU films for protective and safety apparel

The high-stakes challenge of protective apparel

From construction sites to outdoor rescue situations, safety clothing must endure extreme stress without losing structural integrity - and yet still be comfortable to wear.

Typical workwear demands a barrier against liquids, dirt, and chemicals while staying flexible enough to move around in. In a similar way, outdoor apparel needs to block water and contaminants while remaining breathable and lightweight. 

High-stakes protective clothing like bullet- and stab-proof vests, shielding ballistic plates, durable safety aprons and safety boot components all demand wearer comfort along with the security.

Meeting these diverse requirements often means workwear must also retain its strength while accommodating waterproof zippers, seam seals, and reflective materials without sacrificing structural integrity.

TPU films meet the high demands of modern protective apparel

Our thermoplastic polyurethane (TPU) films combine abrasion resistance, high tear strength, and elasticity to deliver long-lasting protection in demanding environments. They act as protective shields that help safeguard sensitive aramid fibers from moisture and UV exposure, thereby supporting consistent ballistic performance. At the same time, the films provide reliable barriers against water and many commonly encountered liquids, while maintaining the flexibility needed for wearer comfort.

In safety clothing and protective apparel, TPU films enable the high-performance laminations with aramid layers and other textiles, resisting delamination under stress. For workwear, they support seam-sealed waterproofing and form durable adhesive layers for zippers, reflective elements, waterproof aprons, and strong bond in safety shoe soles. In outdoor gear, they enable breathable waterproofing that enhances comfort in challenging environments.

Another key advantage is processing versatility. TPU films are compatible with high-frequency welding, lamination, and other advanced processing methods, making them easy to integrate into complex garment designs. This versatility, combined with their protective performance, makes our TPU films a smart choice for protective apparel material.

Tailored solutions for safety-critical applications 

Where standard solutions cannot cope with your needs, Covestro delivers custom-engineered TPU adhesive films tailored to safety-critical applications. Film thickness, hardness, elasticity, and adhesion can be precisely adjusted to meet your protection requirements — whether that means strong bonding for footwear, durable lamination in ballistic vests, or flexible waterproofing for outdoor gear seams. 

Our films can also be designed for breathability and wearer comfort, ensuring protective garments remain practical for long shifts without compromising on safety. 

Beyond materials, Covestro provides application engineering and product development support, working side by side with customers to seamlessly integrate TPU films into innovative garment designs. Across industries, our TPU films unite durability, chemical resistance, waterproofing, comfort, and processing flexibility—without trade-offs.