SantopreneTM Thermoplastic vulcanizates (TPVs) are specialty reactive extrusion blends of polypropylene (PP) as the continuous phase and crosslinked EPDM rubber particles of 1-5 microns as the dispersed phase that are used in a variety of applications including automotive weather-seals, door sealants, wire and cable, hoses etc. TPVs provide the elasticity of rubber and the processability advantages of thermoplastics rendering them the materials of choice relative to thermoset rubber compounds. This paper will discuss the development of a family of step-out TPV products for a variety of applications including but not limited to automotive weatherseal glass run channels (GRC). The new TPV products will be shown to have significantly higher elasticity (e.g. lower compression set, lower tension set and higher resiliency) than commercial TPVs of similar hardness. Extrusion processability data of the new TPVs will be discussed. Surface appearance of the new TPV grades is shown to be excellent for a wide range of processing conditions and die geometries. It is concluded that the new family of TPVs has a significantly enhanced balance of mechanical properties and processability.