How TPU Color PPF Is Made: Exploring Six Common Processes

Discover how TPU color PPF is made. This article explains six major manufacturing processes, from PVC composite to multi-layer fusion, comparing their advantages and limitations to help you better understand automotive film technology.

TPU color PPF is one of the fastest-growing products in the automotive aftermarket. With growing demand, it is expected that in the near future, there could be hundreds of factories around the world producing TPU films. At this stage, several mainstream manufacturing processes have already been formed. To help you understand the differences, we have summarized the six common processes currently used in the market.

 

1. PVC Composite TPU 

This process uses a PVC color layer as the base, with a TPU film cast on top, then coated with a self-healing layer.

 

Caption:PVC composite film can provide rich colors and good gloss, but its weather resistance and stretch performance are relatively weak.

 

Advantages: rich color effects, good surface gloss.

 

Limitations: poor weather resistance, needs improvement; weak stretchability, easy to deform.

 

2. Colored TPU Base Film 

In this process, pigments are added into TPU pellets during extrusion, and the mixture is cast into film directly. Looking at the diagram, you can see it forms a simple three-layer structure: self-healing coat, colored TPU base, and adhesive. The process is relatively straightforward but has been optimized over time.

 

Caption: Pigments are built into the TPU base, giving stable structure and easier installation.

 

Advantages: higher stability in product structure, good consistency between batches, and easier installation for film application.

 

Limitations: color options are still more limited compared to composite methods.

 

3. Adhesive Coloring

In this method, pigments are mixed into the adhesive layer before coating. From the diagram, you can see the bottom layer becomes a colored adhesive, meaning the color comes directly from the glue itself.

Caption: The color comes from the adhesive layer itself, which makes production simple but reduces bonding strength and stability.

 

Advantages: very simple process and easy to produce.

 

Limitations: adding pigments weakens the adhesive’s bonding strength, as the glue mixture is altered. This results in reduced installation performance, lower overall stability, and weaker stretchability of the film.

 

4.Surface Coating 

This process applies a colored coating beneath the transparent TPU base. Looking at the diagram, you can see the colored layer placed just under the TPU film.

 

Caption: Simple to scale up for mass production, with vivid colors, but prone to edge issues and weaker stretchability.

 

Advantages: relatively simple process, making large-scale production possible. It also provides strong visual effects with diverse color options.

 

Limitations: risks of delamination and edge shrinkage, which in severe cases can even lead to the front color layer peeling off. Stretchability is also average.

 

5. Double-die Co-extrusion

This process adopts a double-die extrusion method, meaning it can produce the base layer and the color layer simultaneously. From the diagram, you can see both layers are extruded together, ensuring strong bonding.

 

Caption: Double-die extrusion improves bonding and stability, but has higher cost and limited color flexibility.

 

Advantages: excellent bonding strength between layers, improved film stability, and more reliable long-term durability.

 

Limitations: the process is complex and costly, and it is less suitable for creating a wide variety of color options.

 

6. Multi-layer Fusion 

The multi-layer fusion process is one of the most advanced approaches.

It uses a five-layer structure: self-healing coat, transparent TPU base, TPU color layer, TPU base color layer, and adhesive.

 

 

In this design, the transparent TPU protects the color layer, while the base color layer enhances saturation and prevents the film from looking washed out. Compared with other methods, it offers more flexible color options and makes it easier to produce small-batch customized colors.

The limitation is that production is more complex and costly, but the results bring richer color depth and a finish closer to OEM paint.

 

In this article, we’ve explored six TPU color PPF processes available on the market, highlighting their advantages and limitations.

At our factory, we specialize in the multi-layer fusion process, combining advanced production technology with strict quality control. This ensures films with richer colors, stable performance, and flexible customization — making them a reliable choice for partners worldwide.

We’re always open to sharing insights and exploring cooperation opportunities.