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A single gasket failure can shut down an entire production line. Worse, it can cost you thousands in downtime, rework, and angry clients. Yet most engineers treat gasket selection as an afterthought. Big mistake.
This guide covers everything you need to make smarter gasket decisions:
● What a gasket actually does (and why it matters)
● Materials breakdown: rubber, metal, composite, and more
● How to choose the right gasket for your application
● Custom gasket manufacturing processes explained
● Tips for finding a reliable gasket manufacturer
At TEAM MFG, we've produced millions of custom gaskets for clients across 73 countries. We know what works. Let's dive in.
A gasket is a mechanical seal that sits between two or more mating surfaces. Its job? Prevent leaks. Whether you're dealing with fluids, gases, or contaminants, a well-chosen gasket keeps what's inside in and what's outside out.
Without a gasket, even precision-machined surfaces can't achieve a perfect seal. Microscopic imperfections exist on every flange, housing, and joint. A gasket deforms under compression to fill those gaps, creating a pressure-tight barrier that holds up under real-world conditions.
When you bolt two flanges together, the gasket compresses between them. This compression forces the gasket material to conform to surface irregularities on both sides. The result is a static seal that blocks fluid or gas transfer.
Gaskets are designed for stationary applications. They don't move relative to the surfaces they're sealing. That's what separates them from dynamic seals like O-rings in rotating shafts.
For a gasket to work effectively, it needs three things:
● Adequate compression to fill surface imperfections
● Material compatibility with the media being sealed
● Resistance to operating temperature and pressure
Miss any one of these, and you're looking at a leak.
An industrial gasket does more than just prevent leaks. Depending on your application, it can also:
Function | What It Does |
Sealing | Prevents escape or ingress of fluids and gases |
Anti-vibration | Dampens vibrations between mating components |
Insulation | Blocks heat transfer or electrical conductivity |
Mounting | Provides cushioning between assembled parts |
Contamination barrier | Keeps dust, moisture, and debris out of sensitive systems |
The performance of any precision gasket depends heavily on its material properties. Engineers evaluate gaskets based on:
● Compressibility - how well it deforms under load
● Resilience - its ability to recover after compression cycles
● Creep resistance - resistance to permanent deformation under constant stress
● Chemical resistance - compatibility with process fluids
● Temperature stability - ability to maintain integrity across operating ranges
The higher the compressive load on a gasket, the longer it typically lasts. Most industrial gasket applications involve bolt pressures exceeding 14 MPa (2,000 psi). Under-torqued bolts are a leading cause of premature gasket failure.
People often use "gasket" and "seal" interchangeably. They shouldn't.
● Gaskets seal static joints where surfaces don't move relative to each other. Think pipe flanges, valve bonnets, and engine covers.
● Seals handle dynamic applications where parts rotate or slide. Think piston rings, shaft seals, and hydraulic cylinders.
The distinction matters when you're specifying parts. Order the wrong one, and you'll either have a leak or a component that wears out prematurely.
At TEAM MFG, we manufacture custom gaskets using rubber molding, CNC cutting, and compression molding processes. Our engineering team can help you select the right material and design for your specific operating conditions.
Choosing the right material is everything. Get it wrong, and your gasket will degrade, leak, or fail under operating conditions. Get it right, and you've got a seal that lasts for years.
Gasket materials fall into three broad categories: non-metallic, semi-metallic, and metallic. Each has its place depending on your temperature, pressure, and chemical exposure requirements.
These are your go-to options for low to moderate pressure applications. They're flexible, affordable, and easy to cut into custom shapes.
Rubber gaskets dominate this category. Here's how the most common types stack up:
Material | Temp Range | Best For | Avoid |
Nitrile (Buna-N) | -40°C to +120°C | Oils, fuels, petroleum products | Ozone, sunlight, ketones |
EPDM | -50°C to +150°C | Water, steam, outdoor use | Petroleum oils, hydrocarbons |
Silicone | -60°C to +230°C | Food-grade, medical, extreme temps | Oils, fuels, high abrasion |
Neoprene | -40°C to +120°C | Weather, moderate chemicals, refrigerants | Strong oxidizers |
Viton (FKM) | -20°C to +200°C | Aggressive chemicals, fuels, acids | Ketones, ammonia |
EPDM and nitrile are not interchangeable. EPDM handles water and steam beautifully but will swell and fail in oil. Nitrile does the opposite. Know your media before you specify.
Other non-metallic options include:
● PTFE (Teflon) - exceptional chemical resistance, works with almost everything, but prone to cold flow under sustained compression
● Cork - good for oil sealing in low-pressure automotive applications
● Compressed non-asbestos fiber (CNAF) - handles temps up to 450°C, ideal for steam and moderate chemical exposure
When pressure and temperature climb beyond what rubber can handle, semi-metallic gaskets step in. These combine the strength of metal with the conformability of softer filler materials.
Spiral wound gaskets are the most common type. They consist of alternating layers of metal strip (usually stainless steel) and filler material (typically graphite or PTFE) wound in a spiral pattern. They can handle:
● Pressures up to 2,000 psi
● Temperatures up to 1,000°C (depending on filler)
● Thermal cycling and pressure fluctuations
Kammprofile gaskets feature a solid metal core with concentric serrations covered by soft facing material. They're gaining popularity over spiral wounds because they:
● Require less bolt load to seal
● Offer better blowout resistance
● Can be reused if the core remains intact
● Handle large-diameter applications more reliably
Jacketed gaskets wrap a soft filler in a metal shell. They're commonly used in heat exchangers and high-temperature chemical processing.
For extreme pressure and temperature, solid metal gaskets are the only option. Ring-type joint (RTJ) gaskets are machined from soft iron, stainless steel, or exotic alloys like Inconel. They fit into specially grooved flanges and provide zero-leak sealing in:
● Oil and gas wellheads
● High-pressure pipelines
● Offshore platforms
The tradeoff? They require precise flange machining and higher bolt loads.
Selecting the right rubber gasket isn't guesswork. It's a systematic process of matching material properties to your operating conditions. Here's how to approach it.
Before you even look at materials, answer these questions:
● What's the temperature range? Consider both continuous operating temps and occasional spikes.
● What pressure will the gasket see? Include startup surges and pressure cycling.
● What media contacts the gasket? Identify all fluids, gases, and chemicals in the system.
● Is the application static or dynamic? Gaskets are for static seals. If parts move, you need a different solution.
This is where most failures happen. A gasket that works perfectly with water might dissolve in oil.
● For petroleum-based fluids: Nitrile (Buna-N) is your baseline. It handles most oils, fuels, and hydraulic fluids at a reasonable cost. For harsher chemicals or higher temps, step up to Viton.
● For water and steam: EPDM excels here. It resists hot water, steam, and many dilute acids and bases. For potable water systems, specify WRAS or FDA-approved grades.
● For aggressive chemicals: PTFE offers near-universal chemical resistance. When you need flexibility that PTFE lacks, consider a PTFE-enveloped gasket with an EPDM core.
● For outdoor applications: UV and ozone degrade many rubbers over time. EPDM and neoprene hold up best to weathering.
Gasket hardness is measured on the Shore A scale:
● 40-60 Shore A - Soft, conforms easily to surface irregularities, best for low-pressure applications
● 60-70 Shore A - General-purpose range, balances sealing and durability
● 70-90 Shore A - Firm, resists extrusion under high pressure, requires more bolt load
Thickness matters too. Thinner gaskets (1-3mm) work well on smooth, flat flanges. Rougher or slightly warped surfaces may need thicker gaskets (3-6mm) to fill the gaps.
Depending on your industry, your gasket may need to meet specific standards:
● FDA 21 CFR 177.2600 - Required for food and beverage contact
● WRAS - UK approval for potable water applications
● NORSOK - Oil and gas industry standard
● USP Class VI - Medical and pharmaceutical applications
Don't assume compliance. Verify it with your supplier.
Even the perfect material will fail if installed incorrectly. Consider:
● Flange surface finish - Gaskets need adequate roughness (typically 125-250 microinches) to grip properly
● Bolt torque - Under-torquing leaves gaps; over-torquing crushes the gasket and accelerates creep
● Alignment - Misaligned flanges create uneven compression and localized leaks
Always torque bolts in a star pattern to distribute load evenly across the gasket face. Uneven compression is a leading cause of premature failure.
Use this as a starting point:
Application | Recommended Material |
General water sealing | EPDM |
Fuel and oil systems | Nitrile (Buna-N) |
High-temp steam | Silicone or CNAF |
Corrosive chemicals | Viton or PTFE |
Food processing | FDA-grade silicone or EPDM |
Outdoor/weathering | EPDM or Neoprene |
When in doubt, consult a custom gasket manufacturer who can evaluate your specific conditions and recommend the optimal material.
Gaskets show up everywhere. From the engine in your car to the pipes in a chemical plant, they're the silent workhorses keeping systems sealed and running.
The global gasket market sits at around $10.6 billion and is projected to hit $19.3 billion by 2035. That growth tells you something: as industries become more complex and regulations tighten, demand for reliable sealing solutions keeps climbing.
Here's where gaskets make the biggest impact.
The automotive sector accounts for roughly 35% of the global gasket market. Every vehicle relies on dozens of gaskets to function properly:
● Cylinder head gaskets seal the combustion chamber and prevent coolant and oil from mixing
● Intake manifold gaskets maintain proper air-fuel mixture delivery
● Exhaust gaskets contain high-temperature gases and prevent leaks
● Transmission gaskets keep gear oil where it belongs
● Valve cover gaskets seal the top of the engine block
Modern vehicles, especially electric and hybrid models, are creating new demands for gaskets that provide thermal management and electrical insulation. The shift away from internal combustion engines doesn't mean fewer gaskets. It means different gaskets.
This is where gasket failure can be catastrophic. A single leak in a refinery can lead to fires, environmental contamination, or plant shutdowns costing millions.
Industrial gaskets in this sector must handle:
● Extreme pressures (often exceeding 2,000 psi)
● High temperatures (up to 1,000°C in some processes)
● Corrosive chemicals, acids, and hydrocarbons
● Continuous thermal cycling
Spiral wound gaskets, kammprofile gaskets, and ring-type joint (RTJ) gaskets dominate these applications because they can withstand the punishment.
In aerospace, failure isn't an option. Gaskets in aircraft engines, fuel systems, and hydraulic lines must perform flawlessly at altitude, under pressure fluctuations, and across extreme temperature swings.
Certification requirements are strict. Materials need full traceability, batch documentation, and compliance with standards like AS9100. The aerospace sector is expected to grow at a 6.3% CAGR through 2030, driven by increased air travel and defense spending.
Hygiene is the priority here. Gaskets in food processing equipment must:
● Meet FDA 21 CFR 177.2600 requirements for food contact
● Resist bacterial growth
● Withstand frequent cleaning with hot water, steam, and sanitizing chemicals
● Leave no taste or odor
Silicone and FDA-grade EPDM are the go-to materials. PTFE is also common where chemical resistance matters more than flexibility.
Similar to food processing, but with even tighter controls. Pharmaceutical gaskets need to prevent contamination in sterile environments and may require USP Class VI certification for biocompatibility.
Platinum-cured silicone is standard in medical-grade applications because it produces no byproducts that could contaminate sensitive processes.
Industry | Typical Applications | Common Materials |
Water treatment | Pipe flanges, pump seals, and filtration systems | EPDM, WRAS-approved compounds |
Power generation | Boilers, turbines, steam lines | Graphite, spiral wound, high-temp alloys |
Marine | Engine seals, hull fittings, pump gaskets | Neoprene, nitrile, corrosion-resistant metals |
HVAC | Ductwork, compressors, refrigeration | Neoprene, closed-cell foam, silicone |
Electronics | EMI shielding, dust seals, display mounts | Conductive elastomers, silicone foam |
Off-the-shelf gaskets work for standard applications. But when you're dealing with unique geometries, tight tolerances, or unusual operating conditions, custom manufacturing is the only path forward.
The process starts long before any cutting or molding happens.
Every custom gasket begins with understanding the application. A good manufacturer will ask:
● What are the flange dimensions and surface finish?
● What media will the gasket seal against?
● What are the operating temperature and pressure ranges?
● Are there any certification requirements (FDA, aerospace, etc.)?
From there, the design takes shape. CAD files define the geometry, while material selection ensures compatibility with operating conditions.
Pro tip: Involve your gasket manufacturer early in the design phase. Small changes to radii, thickness, or material can dramatically improve manufacturability and reduce cost.
Not all cutting methods suit all materials or volumes. Here's how the main options compare:
Method | Best For | Tolerances | Tooling Cost |
Die cutting | High-volume runs, simple shapes | ±0.25mm to ±0.63mm | Moderate (requires steel rule die) |
CNC knife cutting | Prototypes, thin films, complex shapes | ±0.25mm | None |
Waterjet cutting | Thick materials, metals, and small runs | ±0.13mm | None |
Compression molding | Complex 3D shapes, high precision | Tight | High (requires custom mold) |
Die cutting uses a steel rule die (think of it as a precision cookie cutter) to stamp gaskets from sheet material. It's fast and cost-effective for volumes in the hundreds or thousands.
The catch? You need to invest in tooling upfront. For simple shapes, steel rule dies are affordable and quick to produce. Complex geometries may require solid milled dies at higher cost.
Also called digital cutting, this method uses computer-controlled blades to cut gaskets directly from CAD files. No tooling required.
CNC knife cutting excels at:
● Rapid prototyping
● Low-volume production
● Thin, flexible materials like silicone and foam
● Complex shapes with tight internal features
Turnaround is fast. Upload a DXF file in the morning, and have parts by afternoon.
Waterjet systems blast a high-pressure stream (up to 90,000 psi) through gasket material with extreme precision. For harder materials, abrasive particles are added to the water stream.
This method handles everything from 1/16" cork to 1" thick rubber to metal gaskets. Tolerances can reach ±0.005", making it ideal for precision applications.
No tooling means no setup fees for small runs.
For gaskets that need three-dimensional shapes or very tight tolerances, compression-molded gaskets are the answer. Raw rubber compound is placed into a heated mold and compressed until it cures into the final shape.
Molding requires custom tooling, which adds upfront cost. But for medium to high volumes, the per-part cost drops significantly.
Reputable manufacturers inspect gaskets at multiple stages:
● Incoming material verification - confirming batch and cure dates, material certifications
● First article inspection - validating dimensions against CAD specs
● In-process checks - monitoring consistency throughout the run
● Final inspection - visual and dimensional verification before shipping
For critical applications, gaskets may undergo additional testing: compression set, chemical resistance, or leak testing under simulated operating conditions.
When die cutting or waterjet won't achieve the geometry you need, molding opens new possibilities.
Compression-molded gaskets work well for:
● O-ring type profiles
● Gaskets with integrated features (lips, ribs, flanges)
● Applications requiring very tight dimensional control
● Medium to high production volumes
The process involves placing uncured rubber into a heated mold cavity. Pressure and heat cause the material to flow and cure into shape. Cycle times range from minutes to hours, depending on material and thickness.
OEM gasket programs often rely on molding to produce consistent, high-volume parts with minimal variation. If you're sourcing thousands of identical gaskets per month, molding typically offers the best balance of quality and cost.
Gaskets are deceptively simple. A flat piece of rubber between two flanges. Yet the wrong material, wrong thickness, or wrong manufacturing method can shut down an entire operation. The details matter more than most engineers realize.
Key takeaways:
● Gaskets create static seals between mating surfaces by deforming under compression to fill microscopic imperfections
● Material selection depends on temperature, pressure, chemical exposure, and industry compliance requirements
● Rubber gaskets (nitrile, EPDM, silicone, Viton) cover most low to moderate pressure applications
● Semi-metallic options like spiral wound and kammprofile gaskets handle extreme pressures and temperatures
● Manufacturing method (die cutting, CNC, waterjet, molding) should match your volume, tolerance, and material needs
● Always verify certifications (FDA, WRAS, AS9100) for regulated industries
TEAM MFG specializes in custom rubber gaskets, compression molded gaskets, and CNC cut gaskets for clients across 73 countries. With ISO 9001 certification, tight tolerances down to ±0.01mm, and delivery as fast as one week, we help engineers move from prototype to production without the headaches. Ready to get started? Request a quote and let our team handle the details.
A gasket fills the gap between two mating surfaces to prevent leaks of fluids or gases. It deforms under compression to seal microscopic imperfections that would otherwise allow media to escape. You'll find gaskets in engines, pipelines, pumps, valves, and virtually any assembly requiring a pressure-tight seal.
Very. A minor gasket leak can escalate quickly into equipment failure, safety hazards, or environmental contamination. In automotive applications, a blown head gasket can destroy an engine. In industrial settings, leaks can cause fires, toxic exposure, or costly unplanned shutdowns. Early detection and replacement are always cheaper than the consequences.
Not always. While many gaskets are made from rubber (nitrile, EPDM, silicone), gaskets can also be manufactured from metal, graphite, PTFE, cork, or composite materials. The key distinction is function: gaskets seal static joints where surfaces don't move relative to each other. Seals typically handle dynamic applications involving rotating or sliding parts.
Gaskets fall into three main categories:
● Non-metallic - Made from rubber, PTFE, cork, or fiber. Best for low to moderate pressure and temperature applications.
● Semi-metallic - Combine metal and soft filler materials (spiral wound, kammprofile, jacketed). Handle high pressure and temperature extremes.
● Metallic - Solid metal construction (ring-type joint, solid metal). Designed for the most demanding pressure and temperature conditions in oil, gas, and power generation.
