Rubber seals and gaskets may seem like small, simple components, but in industrial systems—from pumps and valves to compressors and equipment enclosures—they play a crucial role in maintaining uptime, safety and efficiency. Even a minor failure, such as a leak or a compromised seal, can quickly lead to costly downtime, contamination or safety hazards, impacting both operations and productivity.
Custom Rubber Corp. provides custom molded rubber solutions designed to meet the exacting demands of industrial applications. With expertise in material selection, precision molding and complex part design, we help ensure seals and gaskets perform reliably under pressure, chemical exposure and challenging environmental conditions. Thoughtful design, the right materials and collaboration with experienced suppliers are key to preventing common gasket failures and keeping systems running smoothly.
How and Where Seals and Gaskets Are Used
Rubber gaskets and seals are critical components across nearly every industrial sector, acting as barriers against pressure, fluids, dust and vibration. They protect machinery, systems and sensitive components, helping maintain reliability and safety under demanding conditions.
- Marine & offshore: Corrosion-resistant seals withstand constant exposure to water and fluctuating pressure.
- Electronics & enclosures: Protect sensitive components from moisture and dust.
- Medical & consumer products: Maintain clean, safe interfaces in devices and equipment.
- Industrial machinery & energy: Ensure tight seals in pumps, valves and hydraulic systems, keeping operations efficient and leak-free.
- Automotive & transportation: Prevent leaks in engines, transmissions and HVAC systems, ensuring smooth operation.
Due to constant exposure to stress, pressure, chemicals and harsh conditions, selecting the right gaskets and seals for each application is vital to avoid failures and ensure long-term performance.
Common Causes of Seal and Gasket Failures
Understanding the root causes of seal and gasket failures is the first step in preventing costly downtime and maintaining system reliability. While there are many ways seals can fail, several primary mechanisms account for the majority of issues in industrial applications:
Compression set
Compression set occurs when a rubber component loses its elasticity over time, resulting in permanent deformation and a reduced sealing force. High operating temperatures, prolonged stress or selecting an inappropriate material can accelerate this process. Once a seal experiences compression set, it can no longer maintain an effective barrier, leading to leaks or system inefficiencies.
Stress relaxation
Stress relaxation happens when a compressed rubber seal gradually loses its sealing force even if it isn’t physically deformed. Over time, the rubber relaxes under constant load, reducing contact pressure and potentially allowing leaks. Factors such as high temperature, continuous compression and long-term service conditions can accelerate this process. Selecting materials with high resistance to stress relaxation is crucial for maintaining reliable performance.
Creep
Creep is the slow deformation of rubber under a continuous load. Unlike immediate compression set, creep happens gradually and can lead to permanent gaps between mating surfaces. It is particularly relevant in static sealing applications where a gasket remains compressed for extended periods. Minimizing creep involves choosing the right elastomer, maintaining proper compression ratios, and designing grooves to distribute stress evenly.
Chemical breakdown and material incompatibility
Exposure to harsh chemicals or incompatible fluids can cause rubber to swell, crack or soften, compromising performance. Choosing the right elastomer—such as
EPDM,
Nitrile,
Silicone or specialty compounds—is essential to ensure the gasket or seal withstands the intended environment. Adjusting material choices to the specific chemical, thermal and pressure requirements extends service life and prevents unexpected failures.
Improper installation or misalignment
Even a perfectly designed seal can fail if installed incorrectly. Uneven compression, improper groove dimensions or misaligned surfaces can create gaps and leaks. Ensuring proper assembly, maintaining tight tolerances and following manufacturer installation guidelines helps prevent failures before they occur.
How to Prevent Common Failures
Preventing seal and gasket failures begins with thoughtful design, material selection and rigorous quality control. Following best practices can extend the life of components and keep industrial systems running smoothly.
1. Select the right material for the environment
Matching the elastomer to the operating conditions is vital. Factors such as chemical exposure, temperature extremes and mechanical stress all influence material performance. For example, fluoroelastomers are ideal for fuel and solvent exposure, while silicone performs well across wide temperature ranges. Choosing the right material helps prevent swelling, cracking and compression set.
2. Design for the application
Proper design considerations—including groove geometry, compression ratio and tolerance control—are cruicial for maintaining effective sealing. Working with experienced engineers can optimize these factors, ensuring that gaskets and seals perform reliably over time. Custom Rubber Corp.’s Design & Engineering services help customers tailor parts to their specific applications, minimizing the risk of failure from design-related issues.
3. Ensure proper molding and bonding quality
Precision molding and reliable rubber-to-metal bonding are vital for complex assemblies. Consistent production and expert bonding techniques prevent leaks, delamination and premature wear, ensuring long-lasting performance in demanding applications.
4. Implement quality control and testing
Robust quality control ensures parts meet strict performance standards. Material traceability, visual inspection and real-world testing help identify potential issues before they reach the field.
Custom Rubber Corp.’s ISO 9001 certification demonstrates a commitment to rigorous process control and high-quality outcomes for every project.
When Off-the-Shelf Isn’t Enough
Standard seals and gaskets work well for many applications, but some environments demand more specialized solutions. High-vibration machinery, exposure to aggressive chemicals or extreme pressure and temperature cycles can push off-the-shelf components beyond their limits.
In these cases, custom formulations, precise geometries or specialized materials are essential to maintain reliable performance. Custom-molded parts can be tailored to exact specifications, incorporating features such as color-coded materials for identification, rubber-to-metal bonding for complex assemblies or prototypes to test designs before full production.
Ensuring Reliability from Design to Delivery
Preventing gasket and seal failures starts with careful attention to materials, design and manufacturing quality. Selecting the right elastomer, optimizing geometry and maintaining strict production standards all contribute to reliable, long-lasting performance.
Early collaboration between engineering teams and experienced rubber molders can identify potential challenges before they become problems, ensuring that components meet the demands of even the most demanding applications. At Custom Rubber Corp., this approach is central to our philosophy—delivering solutions with precision, consistency and responsiveness.
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Frequently asked questions
A gasket is typically a flat component used between two surfaces to prevent leakage of fluids or gases, while a seal is often a more flexible or dynamic component designed to prevent leakage in moving parts, such as shafts or pistons. Both serve the purpose of maintaining system integrity under pressure, temperature and chemical exposure.
What causes a gasket or seal to fail prematurely?
Common causes include compression set, stress relaxation, creep, chemical incompatibility and improper installation. Environmental factors such as high temperatures, pressure fluctuations and exposure to aggressive chemicals can accelerate wear and deformation.
How can I prevent my seals and gaskets from failing?
Select the right material for the application, ensure proper design and tolerances, use precision molding and bonding and implement rigorous quality control and testing. Accounting for stress relaxation and creep in long-term applications also helps maintain effective sealing.
How long should a properly designed and installed seal or gasket last?
Service life depends on the material, operating conditions and maintenance. Properly selected and installed seals typically last several years under normal industrial conditions, but high-stress or chemically aggressive environments may require more frequent replacement or specialized materials.