Computer screen shows a gasket drawing example

Our customers often ask us to collaborate with their engineers on a seal’s design to support quality manufacturing for automotive OEMs.

While some seals may appear simple, designing an effective seal is a complex process that involves considering numerous factors—particularly when it comes to rubber seals. Elastomers (rubber) are intricate materials where even slight modifications in their chemical composition can significantly impact manufacturing and performance.

Additionally, like many composite materials, rubber does not exhibit linear behavior. Therefore, skilled design engineers must utilize advanced analysis and adhere to specific requirements to achieve the optimal seal design for each unique application.

With quality always in mind, these are the eight critical stages of our seal design process and an estimate of how long each step takes:

1. Discovery (1 - 3 days)

When you reach out to us with a new program, the first question we will ask is, “What is the seal's application?” because the use case will always drive the design. Our engineers meet with your technical team during this first stage to learn everything we can about the application and solicit additional requirements or requests. We will also ask:

How will the seal be used?
What are the system's operating conditions?
What type of media will be sealed?
What are the application requirements?

Once we understand these parameters, we can select the optimum material and determine the proper molding process.

2. Design Concept Development (1 - 3 days)

Example of Encapsulated Carrier Seal Design

Now that we've identified the seal’s application and requirements, we develop a design concept. The design concept is informed by the discovery process and by our decades of sealing experience. In many cases, we can leverage the work already performed to create an existing design and quickly make modifications to create a successful seal design to match the requirements of your specific application. In contrast, if an entirely new concept is required, it could take longer to determine the seal's requirements.

3. Component Positional Stackup (1 - 14 days)

Statistical Analysis of GD&T in an Assembly

The next stage in the seal design process is to create a positional stackup of the mating surfaces with which the seal will interact. By understanding where the seal fits into the mechanical system, we can verify that the seal design will meet all application requirements.

While we can complete basic vertical stackups relatively quickly, advanced stackups, such as floating vertical designs or horizontal statistical analysis stackups, take additional time.

4. Calculations (1 - 2 days)

Once we've established the application requirements, we perform initial calculations to refine the design shape. Our calculation tools, such as volume fill and maximum/minimum compression, are calibrated to match the precise requirements of the seal's application.

5. Finite Element Analysis (1 - 14 days)

For some designs, the next step in the seal design process is to perform a non-linear Finite Element Analysis (FEA). FEA is a computer simulation used to predict how a gasket or seal will react to real-world forces such as temperature, pressure, and displacement. FEA helps us measure the seal design against the conditions the seal will encounter at the extremes of those real-world forces. We iterate on the design, when necessary, to ensure the final design meets the application requirements.

6. Documentation and Design Approval (3 - 6 days)

Once we adjust the design per the calculations, we use CAD software to produce a 3-D model and a 2-D product drawing that details the seal's dimensions, tolerances, and specifications. Then we present the drawings and comprehensive FEA report to you for final design approval.

Based on the approved design, we finalize which molding process we will use to make the seal, and the design of the machine tooling.

7. Prototype Part Production (6 - 12 weeks)

Now that we have an approved design, we can either order a production tool to start full-scale production or order a prototype tool to prototype parts ahead of production. To ensure a quality product, we only source tools (steel molds) from our trusted US-based tooling partners who know our processes and machines.

8. Environmental Lifecycle Testing (14 - 20 weeks)

Some sealing applications require additional product testing to measure the effect of extreme temperatures applied to the seal over long durations. In this case, we perform durability tests with our in-house thermal test chambers that expose the product to extreme temperatures, ranging from -40°C to 150°C. Lifecycle testing helps verify that the seal does not overly deform, crack, split, or leak under these extreme conditions.

The Morgan Polymer Seals Advantage

Seal design, FEA, and product testing are vital steps to manufacturing a quality gasket, so it's essential to choose a manufacturing partner with complete technical capabilities and considerable engineering experience.

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This article has been edited and re-published from its original appearance, written by our design engineer, Thomas Morgan, in May 2021.

Automotive Gasket Design: Process and Timeline