Optimizing Plasticizer Selection: Insights Into Thermoplastic Polyurethane Performance and Sustainability

ABSTRACT Thermoplastic polyurethanes (TPUs) serve as versatile materials bridging rubbers and plastics, increasingly replacing conventional polymeric materials and rubbers in lightweight, cost‐effective, and high‐performance applications. Plasticizers are very useful for tailoring TPU properties to meet application‐specific requirements. This study investigates the plasticization of a polyether‐based TPU using plasticizers with different chemical structures, including benzoate‐ and phosphate‐based types, alongside a bio‐based alternative to move toward greener and more sustainable scenarios. Thermal and mechanical assessments revealed that low molecular weight benzoate plasticizers provided optimal performance with low volatility, offering a viable substitute for the industry‐standard plasticizer. Conversely, high molecular weight benzoates and flame‐retardant phosphate‐based plasticizers exhibited reduced efficacy. The bio‐based plasticizer demonstrated promising potential at concentrations below 30%, although saturation effects limited its performance at higher dosages. These findings highlight the critical role of plasticizer selection and optimization in achieving targeted TPU properties, with implications for sustainable material development in industrial applications.