Customer Story: Collaborative Design for Automotive OEMs

View of the ‘mechanical seal’ portion of the capless refueling system

Sometimes a customer asks us to manufacture a gasket that is already designed, and sometimes we are asked to collaborate on the seal design. This case study examines the collaboration between General Motors (GM), Morgan Polymer Seals, and Illinois Tool Works (ITW) to develop a capless refueling system for the Cadillac CT6.

The project tackled key challenges in automotive design, including emissions reduction, cold weather performance, and maintaining the vehicle's design integrity.

GM aimed to enhance the CT6’s refueling system to eliminate the gas cap and ensure a tightly sealed fuel system. This resulted in a mechanical seal that prevents vapor leakage, directing emissions through the vehicle’s carbon canister.

A crucial aspect was the system's functionality in extreme temperatures. Morgan Polymer Seals developed a proprietary FKM fluorocarbon-based compound that remains flexible at temperatures as low as -40°C, showcasing significant advancements in material engineering.

The study also highlights the design and manufacturing processes, particularly the challenges of injection molding high-viscosity FKM material. Precision manufacturing techniques minimized waste, crucial given the material's high cost.

Collaboration between GM, Morgan Polymer Seals, and ITW was key to overcoming technical challenges and achieving successful implementation. This case study underscores the importance of interdisciplinary cooperation in automotive innovation, providing valuable insights for enhancing performance, compliance, and sustainability in future vehicle designs.

Click below to read the entire customer story.

View of the body seal installed on the capless refueling system