PFA & PTFE: The Differences Explained – Which Should You Choose and When?
Fluoropolymers are renowned across many industries for their exceptional chemical resistance, heat stability, and durability. Two of the most recognised materials in this family are PTFE (Polytetrafluoroethylene) and PFA (Perfluoroalkoxy alkane). At first glance, they appear quite similar — yet their differences can make or break a technical application. In this article, we explain the distinctions clearly and help you decide which material best suits your engineering or process needs.
What Are PTFE and PFA?
PTFE: The Classic Fluoropolymer
PTFE, better known under the brand name Teflon®, has been a trusted material since the 1940s in both household and industrial applications. It is chemically inert, resistant to high temperatures, and features an extremely low coefficient of friction.
PFA: The Modern Counterpart
PFA is a copolymer of tetrafluoroethylene (TFE) and perfluoroalkoxy vinyl ether (PAVE). It retains the chemical and thermal performance of PTFE but adds one key advantage: thermoplastic processability. This means PFA can be extruded, injection moulded, or thermoformed — a property that PTFE lacks — making it much more versatile for complex or precision components.
Properties Compared
Here’s an overview of the key properties of PTFE and PFA:
|
Property |
PTFE |
PFA |
|
Temperature resistance |
Up to approx. 260 °C |
Up to approx. 260 °C |
|
Chemical inertness |
Very high – resistant to nearly all substances |
Equal or higher |
|
Electrical insulation |
Excellent |
Excellent |
|
Friction coefficient |
Exceptionally low |
Very low |
|
UV resistance |
Very good |
Very good |
|
Processability |
Compression moulding and sintering only |
Thermoplastic: extrusion, injection moulding, etc. |
|
Mechanical strength |
Good but brittle in thin sections |
Better for thin-walled components |
|
Surface finish |
Matte, rough texture |
Smoother and glossier possible |
Processing and Forming
One of the most significant differences between PTFE and PFA lies in how they are processed and shaped.
PTFE: Challenging to Form
PTFE is a non-melt-processable polymer. It cannot be cast, extruded, or injection moulded like most other plastics. Instead, it must be compressed into shape and then sintered (heated without melting). This limits design flexibility and increases production costs for complex geometries.
PFA: The Thermoplastic Advantage
PFA, in contrast, can be melt-processed. It allows for extrusion, injection moulding, and thermoforming, making it far more suitable for complex geometries, thin-walled parts, or mass production. It can also be finished to achieve smoother and glossier surfaces, which are advantageous in high-purity and hygienic applications.
Practical Applications
Both materials perform exceptionally in demanding environments, but their use cases differ based on technical and economic requirements.
Typical Applications of PTFE
- Gaskets and sealing elements in chemical installations
- Non-stick coatings for cookware and bakeware
- Cable insulation in electrical and electronic systems
- Tubing for aggressive fluids in process industries
Typical Applications of PFA
- Cleanroom and semiconductor industry: piping for ultra-pure liquids
- High-purity chemical transfer systems in the pharmaceutical sector
- Injection-moulded components requiring tight tolerances
- Food industry: piping and valves exposed to repeated sterilisation
Which Material Should You Choose?
Here are a few practical guidelines to help determine the right material for your project:
|
Application Requirement |
Recommended Material |
|
High chemical resistance |
Both are suitable |
|
High temperature resistance |
Both are suitable |
|
Complex shapes or injection moulding |
Choose PFA |
|
Precision or mass production |
Choose PFA |
|
Cost-sensitive, simple designs |
Choose PTFE |
|
Maximum wear resistance |
PTFE slightly preferable |
|
Ultra-smooth surface required |
PFA performs better |
|
Fluid transport in cleanrooms |
PFA is the standard choice |
Summary
- Choose PTFE for simple, robust applications where design complexity is minimal.
- Choose PFA when you need greater design freedom, higher precision, or cleanroom compatibility.
Service Life and Reliability
Both materials deliver excellent longevity, especially in chemically aggressive environments. Their low friction coefficient prevents build-up of product residues or contamination, ensuring long-term performance and reliability.
PFA is often preferred in specific applications thanks to its enhanced mechanical strength and smoother surface finish, which helps prevent biofilm formation in piping and fluid systems.
Conclusion
PTFE and PFA are both top-tier materials within the fluoropolymer family — but they are not interchangeable. PTFE is proven, robust, and cost-efficient, while PFA offers greater design flexibility, superior processability, and suitability for high-purity environments. Ultimately, your choice depends on the specific application, desired performance, and production method.
Would you like to know if PFA is the right choice for your project? Contact our PFA specialists or request a free technical consultation today.