PTFE vs PFA

PTFE vs PFA

Updated 12/02/2026

Fluoropolymers are a unique family of high-performance materials known for their exceptional chemical resistance, temperature capability and electrical insulation properties.

They are widely used across critical industries, including:

  • Oil & Gas

  • Aerospace

  • Hydrogen & Renewables

  • Semiconductor

  • Industrial processing

  • Medical

Among the most well-known fluoropolymers are PTFE, PFA and FEP. While they share a common fluorinated backbone and many similar properties, their processing characteristics and performance limits differ in ways that can significantly affect application suitability.

So what exactly separates them?

Table of Contents

PTFE: Properties, Advantages & Considerations

PFA: Properties, Advantages & Considerations

FEP: Properties, Advantages & Considerations

Property Comparison

How To Choose

Industry Considerations

Frequently Asked Questions (FAQs)

PTFE (Polytetrafluoroethylene)

PTFE is the original and most widely recognised fluoropolymer.

Key Properties

  • Continuous service temperature: up to ~260°C

  • Virtually chemically inert

  • Extremely low coefficient of friction (0.03–0.05)

  • Excellent dielectric strength (50–100 kV/mm)

  • Outstanding performance at cryogenic temperatures

  • High elongation and flexibility

PTFE’s carbon-fluorine bonds are among the strongest in organic chemistry, giving it exceptional resistance to aggressive chemicals, including strong acids and solvents.

Limitations

The main processing limitation of PTFE is that it does not flow in the molten state. Its extremely high melt viscosity prevents conventional injection moulding.

Instead, PTFE is:

  • Compression moulded

  • Ram extruded

  • Sintered

This restricts complex geometry formation and can influence cost and tolerances.

Typical Applications

  • Valve seats and seals in Oil & Gas

  • Chemical processing linings

  • Semiconductor fluid handling

  • Cryogenic LNG seals

  • Electrical insulation systems

PTFE is often selected where chemical inertness and ultra-low friction are the primary design drivers.

PFA (Perfluoroalkoxy)

PFA is a fully fluorinated copolymer developed to provide PTFE-like performance with melt processability.

Key Properties

  • Continuous service temperature: up to ~260°C

  • Excellent chemical resistance (similar to PTFE)

  • Melt-processable (injection mouldable and extrudable)

  • Improved creep resistance compared to PTFE

  • Lower void content (improved permeability resistance)

  • Good clarity (in some grades)

Because PFA can be melt processed, it allows:

  • Complex component geometries

  • Welded assemblies

  • Improved consistency in high-purity applications

Chemical Considerations

Although PFA exhibits outstanding chemical resistance, it can react with:

  • Fluorine gas at elevated temperatures

  • Molten alkali metals

Typical Applications

  • Semiconductor chemical handling systems

  • High-purity piping and tubing

  • Aerospace fuel systems

  • Hydrogen valve linings

  • Heat exchangers

PFA is frequently chosen where high temperature capability and chemical resistance are required, but complex shapes or welded systems are also needed.

FEP (Fluorinated Ethylene Propylene)

FEP is another melt-processable fluoropolymer and shares many properties with PTFE.

Key Properties

  • Continuous service temperature: up to ~200°C

  • Excellent chemical resistance

  • Good dielectric strength (~55 kV/mm)

  • Melt-processable

  • Transparent in many grades

  • Remains flexible at cryogenic temperatures (down to ~ -200°C)

Compared to PTFE, FEP:

  • Has a lower maximum operating temperature

  • Is easier to process

  • Can be welded and thermoformed

Typical Applications

  • Wire and cable insulation (aerospace and industrial)

  • Transparent chemical tubing

  • Liners and coatings

  • Cryogenic seals

  • Medical and laboratory components

FEP is often selected when ease of processing and fabrication flexibility are priorities, and where operating temperatures remain below 200°C.

Property Comparison

Specification PTFE PFA FEP Performance Insight
Chemical Resistance Virtually inert Virtually inert Excellent All highly resistant; PTFE/PFA slightly superior
Continuous Temperature ~260°C ~260°C ~200°C PFA matches PTFE; FEP lower
Dielectric Strength 50–100 kV/mm ~55 kV/mm ~55 kV/mm All strong electrical insulators
Tensile Strength 25–35 MPa 28–31 MPa 20–30 MPa Comparable
Coefficient of Friction 0.03–0.05 0.05–0.08 0.05–0.08 PTFE lowest
Flexural Modulus ~495 MPa ~690 MPa ~600 MPa PFA slightly stiffer
Thermal Expansion ~14 × 10⁻⁵ /K ~12 × 10⁻⁵ /K ~12–13 × 10⁻⁵ /K Similar behaviour
Elongation 350–400% 260–300% 250–350% PTFE most flexible
Processing Sintered Melt-processable Melt-processable PFA/FEP easier to fabricate
Relative Cost Moderate High Moderate–High PFA typically highest

The information in this table represents typical figures intended for reference and comparison purposes only 

How to Choose Between PTFE, PFA and FEP

Choose PTFE when:

  • Maximum chemical resistance is required

  • Ultra-low friction is critical

  • Cryogenic flexibility is needed

  • Electrical insulation performance is paramount

  • Cost sensitivity is a factor

Choose PFA when:

  • High temperature capability (~260°C) is required

  • Melt processing or welding is necessary

  • Improved creep resistance is important

  • High purity and low permeability are critical (e.g. semiconductor, hydrogen systems)

Choose FEP when:

  • Operating temperature remains below 200°C

  • Transparency is beneficial

  • Fabrication flexibility is required

  • Wire and cable insulation is needed

Industry Considerations

Oil & Gas

  • PTFE for aggressive sealing environments

  • PFA for high-temperature chemical handling

  • FEP for lined systems and electrical insulation

Aerospace

  • FEP for wire insulation

  • PTFE for low-friction components

  • PFA for high-performance fluid systems

Hydrogen & Renewables

  • PFA and PTFE commonly used in valve linings and seals

  • Material compatibility must consider permeation and pressure cycling

Semiconductor

  • PFA preferred for ultra-pure chemical handling systems

  • PTFE used in static sealing and fluid management

Frequently Asked Questions (FAQs)

What is the main difference between PTFE and PFA?

The primary difference is processability.
PTFE cannot be melt processed, while PFA can be injection moulded and welded. PFA also offers slightly improved creep resistance.

Is FEP as chemically resistant as PTFE?

FEP offers excellent chemical resistance, but PTFE and PFA generally provide the highest level of chemical inertness.

Which fluoropolymer has the highest temperature resistance?

PTFE and PFA both operate continuously up to approximately 260°C. FEP is typically limited to around 200°C.

Which fluoropolymer is best for semiconductor applications?

PFA is commonly preferred due to its melt-processability, purity and low permeability. PTFE is also widely used in static sealing.

Can fluoropolymers be used in hydrogen systems?

Yes. PTFE and PFA are widely used in hydrogen valves and sealing systems. Material testing is recommended to evaluate permeation and pressure cycling behaviour.

Why is PFA more expensive than PTFE?

PFA’s melt-processability and enhanced performance characteristics require more complex manufacturing processes, contributing to higher material cost.

To find out how we can support your projects, contact info@fluorocarbon.co.uk

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