TPU/PC Substrates in Printed Electronics for Wearable Healthcare 

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TPU/PC Substrates in Printed Electronics for Wearable Healthcare 

As medical devices advance and the demand for flexible wearable technologies continues to grow, new materials are 
being developed to meet these requirements. Thermoplastic polyurethane (TPU) and polycarbonate (PC) films are 
increasingly being used to create lightweight, durable, and functional electronic interfaces. TPU is highly flexible and resistant to tearing, combining the properties of hard plastics and soft silicones to provide excellent impact resistance [1]. However, TPU is less resistant to sharp objects and may experience stretching over time. In contrast,

PC offers a high strength-to-weight ratio, excellent heat resistance, and scratch resistance, making it an extremely durable material [1]. Its primary limitations are reduced flexibility and susceptibility to cracking under certain conditions. When combined, TPU and PC provide an effective balance of flexibility and robustness for wearable electronic applications. 

Printed electronics have become a major contributor to innovative medical device design by enabling the integration of conductive inks and electronic components directly onto flexible substrates. Covestro offers several products that support this technology, allowing a wide variety of devices to be manufactured for different applications. Common conductive inks include silver-based inks, which provide high electrical conductivity, and copper-based inks, which offer a lower-cost alternative [2]. Covestro's substrate options include rigid Makrofol polycarbonate (PC) films and highly flexible Platilon thermoplastic polyurethane (TPU) films. 

These materials have enabled the development of innovative applications such as smart shoe insoles, robotic tactile sensors, clothing, and wearable monitoring patches. By providing versatile substrates for printed electronics, TPU 
and PC films are helping advance the next generation of comfortable, durable, and functional wearable medical 
devices.

Article written by Jennifer Joanna-Joan Villeneuve,
M.ESc Biomedical Engineering Candidate, B.ESc Mechatronic Systems & B.ESc Biomedical Engineering

 
References 
[1] Evelatus, “PC and TPU: The science behind phone case materials,” New Brand of Mobile Phone Accessories, 
https://evelatus.com/pc-and-tpu-the-science-behind-phone-case-materials (accessed Jun. 14, 2026).  
[2] “Printed Electronics,” Covestro AG, https://solutions.covestro.com/en/highlights/articles/theme/processing
technology/printed
electronics?utm_id=13564377&utm_source=organic_press_release&utm_medium=organic&utm_content=covestr
oinsulectropartnership-techblick2026 (accessed Jun. 14, 2026). 

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