TPE Car Mats: Injection vs. Vacuum Forming—Why Europe & America Favor Injection Molding

In the adult world, apart from family, the longest companion is often the car that shelters us from wind and rain. Everyone has their own special attachment to their car, and the ways they protect it vary.

Take car floor mats, for example. The original intention is to protect the interior and make cleaning easier. However, as cars become more expensive, people have grown more meticulous about their care. Initially, factory-installed mats were just meant to prevent dirt, but now fully enclosed leather mats are trending in China, almost as if the entire cabin is being wrapped up.

In the well-developed automotive cultures of Europe and America, large enclosed leather mats have never been popular. Instead, rubber or TPE (thermoplastic elastomer) mats are commonly used. Many car manufacturers, such as BMW and Volvo, even develop their own TPE mats.

Compared to traditional rubber or leather mats, TPE mats are more environmentally friendly, designed more thoughtfully to avoid interfering with pedals, and easier to maintain.

Currently, TPE mats are divided into two manufacturing processes: injection molding and vacuum forming.

In foreign markets, many TPE mats use vacuum forming, while original car manufacturers exclusively opt for injection molding.

The mold cost for vacuum forming a single car model ranges from 10,000 to 20,000 RMB, whereas injection molding costs around 300,000 RMB per model.

First, let’s discuss the differences between injection molding and vacuum forming:

Material Differences
Injection molding requires 100% pure TPE material, while vacuum forming often mixes TPO or TPV with TPE-like compounds. In terms of material purity, vacuum forming falls short of injection molding.

As a result, one-piece injection-molded TPE mats have a softer, more rubber-like texture and better foot comfort.

Vacuum-formed products, on the other hand, tend to be harder, more plastic-like, and can make the heels feel fatigued during long drives.

Durability Differences
Injection-molded TPE mats are resilient. If they deform over time, pouring boiling water over them or leaving them in the sun for a while can restore their original shape and fit.

Vacuum-formed mats, however, may start to curl at the edges after 1–2 years of use and cannot be restored.

Vacuum-formed mats used by foreign car owners

The difference in performance stems from their manufacturing processes:

Injection molding involves liquefying granular raw material at high temperatures in an injection molding machine before shaping it in a mold.

Vacuum forming starts with a flat sheet of material, which is then heated, softened, and suction-formed onto a mold to cool and set.

In other words, injection-molded products inherently have a three-dimensional shape, while vacuum-formed products only take shape on one side. Naturally, the latter’s ability to recover is far inferior to the former’s.