TR90 vs PC vs TPU vs metal: choosing frame materials for sports sunglasses
A practical comparison of TR90, polycarbonate, TPU, metal and acetate frames for sports eyewear, including weight, flexibility, cost, colours and best uses.
Short answer: TR90 is the default for performance sports frames because it is light, flexible and holds up in heat and cold. PC is cheaper and rigid, so it suits promotional and lifestyle sunglasses. TPU is soft and rubbery and is used for goggles, tactical frames and kids’ models. Metal and acetate are used for fashion and optical frames rather than high-impact sport.
The short version
| Material | Weight | Flex | Cost | Best for |
|---|---|---|---|---|
| TR90 (nylon-based thermoplastic) | Very light | High, springs back | Mid | Cycling, running, ball sports, kids |
| PC (polycarbonate) | Light | Low, rigid | Low | Promotional, lifestyle, fashion sport |
| TPU | Light | Very high, rubbery | Low–mid | Goggles, tactical, kids, straps |
| Metal (alloy, stainless, titanium) | Light to mid | Medium | Mid–high | Fashion, optical, aviators |
| Acetate | Mid | Low | Mid–high | Fashion and optical frames |
TR90
TR90 is a thermoplastic nylon developed for eyewear. It is the material behind most of our cycling glasses and running sunglasses. It weighs roughly a sixth less than many acetates for the same shape, flexes without cracking, and resists heat deformation when a pair is left on a car dashboard. TR90 takes matte, gloss and rubber-touch finishes, and supports two-tone spraying.
PC (polycarbonate)
PC frames are rigid and inexpensive to mould, with crisp edges and a high gloss. They are a sensible choice when price matters more than all-day comfort, for example event giveaways, tourism retail or entry-level lifestyle lines. Do not confuse a PC frame with a PC lens: polycarbonate lenses are the impact-resistant standard for almost all sports lenses.
TPU
TPU is soft and grippy. We use it for ski goggles, motocross goggles, many tactical frames, and for one-piece flexible kids’ frames that can be twisted without breaking.
Metal and acetate
Metal and acetate belong in fashion and optical lines. They look premium and adjust well for fit, but they add weight and do not survive impacts the way TR90 does. You will find them in our fashion sunglasses and optical frames.
Details that matter more than the headline material
- Nose pads and temple tips. Hydrophilic rubber grips harder when wet. Ask for it on anything sold as a running or cycling model.
- Hinges. Spring hinges and screwless hinges reduce warranty returns.
- Lens retention. Magnetic, snap-in or pull-out lens systems decide how easily customers can swap lenses.
- Finish durability. Request a rub and sweat test on sprayed colours before bulk production.
Need help picking? Tell us the sport, price point and market and we will shortlist frames that already have moulds.
Frequently asked questions
Is TR90 better than polycarbonate for sunglasses frames?
For sports, usually yes. TR90 bends instead of snapping and stays comfortable in heat. Polycarbonate frames are cheaper and take glossy finishes well, so they make sense for promotional or price-led ranges.
Can TR90 frames be painted in custom colours?
Yes. TR90 is injected in a base colour and then sprayed, rubber-coated or water-transfer printed. Pantone matching is possible on most models from the standard MOQ.
What material are motocross and ski goggle frames made of?
Goggle frames are usually TPU, sometimes with a TPU-PU blend, because it stays flexible in cold temperatures and seals against the face with foam.
