Gaskets are an unsung hero of manufacturing. They don’t push the envelope, they don’t break new barriers, but they do one thing really, really well: keep the entire machine, product or part working as intended.
For these heroes, choosing the right material is the source of their power. Not all gaskets will be used in the same application, and not all will need to do the same thing – so they shouldn’t all be made of the same material.
Explore our guide for material selection on your die-cut gaskets.
Related Content: The Power of Custom Die Cutting for Your Production Needs
Considerations for Choosing a Die-Cut Gasket Material
Before you can choose the right material for your gaskets, there are a few considerations to keep in mind. How a gasket will be used and the conditions it will be subjected to will impact material selection and design. Questions to ask include:
- What external and internal conditions will this gasket be subjected to? (Heat, pressure, UV exposure, etc.)
- Will this gasket be directly or indirectly subjected to liquids, corrosive materials or abrasive materials?
- Are there specific industry standards and/or health and safety standards that this gasket will need to meet?
- Do you want to apply pressure-sensitive adhesive backing to the gasket?
When reviewing the options below, keep your answers to these questions in mind.
Best Materials to Use for Die-Cut Gaskets
Solid Materials
Choosing a solid material for a gasket is the right choice when a gasket will be subjected to high compression forces and will need to resist them. Silicone is one of the most common choices for a solid gasket, because of its resistance to temperature extremes (up to 500°F), UV and flame. Their rigidity also means an extended lifespan over more flexible materials.
Related Content: Silicone Selection Guide for Gaskets and Seals
Solid gaskets offer greater durability and a longer lifespan. They also can endure higher compression forces than other materials, which makes them ideal for applications that require handling significant compression.
For that reason, it’s a common choice for applications in the automotive, aerospace and industrial industries for OEMs. One example application is to use a solid silicone gasket as a part of the thermal shielding on a recreational vehicle. The gasket will retain its shape and function even when exposed to extreme temperatures, water and UV.
Sponges and Foams
Sponges and foams are ideal for gaskets where the intended application is to reduce the impact of compressional forces on housings. They are more flexible and have a higher indentation load deflection compared to solid materials. Sponge and foam gaskets also can be used to create simple seals where a high degree of environmental resistance is not necessary.
Sponge gaskets typically have a higher compressional resistance than foam gaskets, but foam can have better cushioning properties. Foam can also allow air to flow through the gasket, while trapping larger contaminants.
Related Content: Automotive NVH Foam – What Is It, and How Does It Work?
Sponges and foams should be considered for gaskets that need to provide cushioning to a more fragile housing. They should also be considered for applications to reduce NVH (noise, vibration, and harshness).
One example of a sponge gasket in practice is inside a cabin door of a vehicle, to help control vibration.
Rubbers
Rubber gaskets will provide less rigidity than a solid material, but can provide a tight seal against liquids. They are also resistant to UV.
EDPM (Ethylene Propylene Diene Monomer) and Neoprene are the two most common rubber choices for gaskets. EDPM is extremely resistant to weathering, temperature and heat. Neoprene is better at resisting chemical, oils and liquids.
Related Content: What’s the Difference Between EPDM and Neoprene Rubber?
Rubber gaskets should be considered for applications where creating a seal is critical.
Other Materials
A majority of gaskets will be made from plastic – whether it’s a solid plastic application, a more porous plastic like foam or a compound plastic. In a vast majority of use cases, plastics are the best option to achieve desired outcomes while also remaining cost-effective.
However, there are some cases where a non-plastic material may be selected or combined with plastic. These include:
- Cork – Has used been used historically in automotive applications because of a high degree of flexibility and compressibility. However, to use in a gasketing application it will need to be blended with a plastic to ensure resistance and a longer lifespan. These cork blends can perform similarly to rubber at a much lower cost, but also are much more prone to wear and tear. For that reason, modern automotive manufacturers typically use rubber instead.
- Felt – A wool-based material, felt gaskets are not resistant to heat, pressure or liquids. However, they do provide vibration and abrasion resistance. They will often need to be replaced frequently. Felt gaskets could be used in applications where low cost is the primary concern, not function.
- Flexible graphite – if you have extreme heat situations, graphite offers similar properties of solid plastic but with an even higher heat resistance – up to 850°F in oxygen environments and up to 5400°F in oxygen-free environments. However, graphite is much more costly than silicone, so it’s not a practical choice for less extreme temperatures.
Choose the Right Option with Industrial Custom Products
Since 1955, ICP has grown to become an award-winning leader in prototyping, developing, and manufacturing high-quality plastic and flexible products. The foundation of our company is our absolute, unyielding commitment to high-quality work and on-time delivery.
Contact us and speak with an engineer about your project at (612) 781-2255, or request a quote online. You will receive a prompt response.
References:
Gasket Materials Editorial – Industrial Quick Search
Common Die Cutting Applications – Thomasnet.com
BISCO® Silicones – Rogers Corporation
Industrial Custom Products is a one-stop-shop for custom manufacturing and plastic fabrication, including: prototyping and product development, die cutting and dieless knife cutting, thermoforming and vacuum forming, large part thermoforming, CNC plastic routing, fabrication and assembly and drape forming.
