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Polymer microspheres are tiny game-changers in countless sectors from coatings to composites, plastics to automotive. In this deep dive, we’ll explore unexpanded vs. expanded microspheres, their standout features, real‑world use cases, and how they deliver cost‑effective performance for industrial users.

Microspheres are microscopic hollow polymeric spheres (typically 1–100 µm) consisting of a thermoplastic shell encapsulating a low‑boiling hydrocarbon. When heated, the shell softens and expands, dramatically increasing in volume while remaining lightweight and resilient

Unexpanded Microspheres:

• These act as blowing agents ideal for printing inks, thermoplastics, paper & boards, and non-woven applications.

Expanded Microspheres:

• Fully expanded, closed-cell spheres are used as lightweight fillers in cultured marble, body fillers, paints, cable jellies, thermosetting resins, and more

• Ultra-Low Density & Volume Gain: Expansion ratios between 40–80x produce ultra-light fills, enhancing strength without weight 

• Cost-Savings & Material Efficiency: Reduce resin or polymer usage while maintaining structural integrity.

• Improved Insulation & Resilience: Closed-cell structure provides thermal barriers, sound dampening, and pressure absorption.

• Surface Enhancement & Adhesion: Boost adhesion, improve surface finish, and increase bulk or stiffness in coatings and paper.

• Versatility Across Processes: Compatible with coatings, spraying, impregnation, molding, extrusion, injection molding, and more 

• Over 30 years of specialized experience with thermoplastic microspheres. 

• Both unexpanded and expanded grades for tailored performance.

• Proven efficiency in volume increase, thermal control, and adhesion.

• Support through product selection and process integration.

• Choose form & grade based on process—blowing vs filler needs.

• Process compatibility ensures seamless integration (coating, molding, extrusion).

• Benefit-rich additions: lower weight, insulation, texture, and adhesion.

• Partner for success: expert consultation, custom troubleshooting, seamless sourcing.

• Check out Unexpanded Microspheres to discover our blowing agent.

• Visit Expanded Microspheres to explore our lightweight filler.