Choosing the right gasket is crucial for protecting your equipment, extending its lifespan, and preventing injuries. With the number of gasket materials available, it can be hard to choose the best option for your equipment. You will need to consider factors like the environment, industry requirements, operating temperatures, and material compatibility to choose the appropriate gasket.
American Flexible Products has more than 30 years of experience fabricating custom gaskets. As a 3M™ Preferred Converter and Rogers Corporation Preferred Converter, we can find the best material for any application. Let’s explore your options and what to consider below.
Choosing a Gasket Material: Questions to Ask
Gaskets are used across countless industries, and with a vast array of specifications to meet, materials can rarely be used interchangeably. Before learning about the specifications of different materials, it helps to ask yourself questions about how the gasket will need to perform for your unique application:
- Does the gasket need to seal oil, water, gas, or chemicals?
- What temperature range does the gasket need to operate in?
- Does the gasket need to withstand pressure, and does the pressure cycle?
- Does the material need to meet industry-specific standards like FDA or MIL-Spec requirements?
- Will the material be exposed to UV or other environmental conditions?
- Is off-gassing an issue you need to avoid for your application?
With these factors in mind, we’ll examine how rubber, foam, and plastic materials compare to one another. Keep in mind that there are numerous different types of material within each category. AFP can help you choose the exact material you need. Send us a message to get started.
Rubber Gaskets
Rubber is a broad category that includes many different materials. For example, rubber gasket materials include neoprene, silicone, and ethylene propylene diene monomer (EPDM).
When choosing a gasket, rubber is a great option for applications that call for durability and flexibility. Rubber can flex and conform to unique flange shapes, making these gaskets easy to install. Their resistance to chemicals and UV radiation makes them an ideal choice for a wide range of industries.
Below is a comparison of popular rubber gasket materials we fabricate at AFP:
Product |
Temp Range |
Benefits |
Common Uses |
| Nitrile Rubber | -40°F to 250°F (-40°C to 121°C) | Excellent resistance to oil, fuel, and grease; high tensile strength and flexibility. | Hydraulic systems, food processing, petrochemical applications, and engines. |
| Silicone Gaskets | -67°F to 392°F
(-55°C to 200°C) |
Low compression set, high tear strength, resistance to fluids, and high temperature resistance. | High-precision electronics, electric vehicles, and high-performance sealing applications. |
| EPDM Gaskets | -40°F to 200°F (-40°C to 93°C) | Resistant to weather, UV radiation, and chemicals; high flexibility, and durability. | Roofing, automotive, and industrial weatherproofing. |
| Neoprene Gaskets | -40°F to 230°F (-40°C to 110°C) | Resistant to alkalis, UV radiation, grease, oils, and petroleum-based solvents; offers flexibility and twistability without becoming damaged. | HVAC, marine, construction, and food processing applications. |
Foam Gaskets
Like rubber, foam gaskets come in numerous different materials. To make material selection more difficult, foam can be made of the same materials used for rubber gaskets, such as silicone, EPDM, and neoprene.
The main difference lies in the structure of the material. Rubber is dense and more resistant to abrasion, while foam is designed to have air bubbles within the material to provide more cushioning.
When choosing a foam gasket, it also helps to understand the differences between open-cell and closed-cell foam.
- Open-cell foam is comprised of open bubbles that are not trapped within the material. It is lightweight, easy to compress, and allows for air and water to flow freely through it.
- Closed-cell foam is denser because the bubbles are trapped within the material. As such, it is more resistant to abrasion, more rigid, and water-resistant.
Here is a comparison of some of the most popular foam gaskets from AFP:
Product |
Temp Range |
Benefits |
Common Uses |
| Bisco Silicone Foam | -67°F to 392°F
(-55°C to 200°C) |
Unmatched compression set resistance, compliance with stringent smoke and toxicity regulations, and compliance with the highest UL-94 flame ratings. | Aerospace, defense, medical, automotive, and electronics. |
| Bisco Bun Silicones | -67°F to 392°F (-55°C to 200°C) | Flame, smoke, and toxicity resistance, low compression set, and UV resistance. | Sealing, insulation, and cushioning (particularly aircraft and passenger train seating). |
| Rogers PORON® Foam | -40°F to 194°F
(-55°C to 90°C) |
Low out-gassing, high durability, long performance, flame retardant, and chemical resistant. | Space and satellite industries, defense applications, automotive, and medical devices. |
| Neoprene Foam | -40°F to 200°F (-55°C to 93°C) | High durability, good shock absorption, and resistant to ozone, UV, chemicals, water, and oil. | Automotive and marine industries, electrical enclosures, and construction applications. |
Plastic Gaskets
Plastic is another broad category of gasket materials. Whereas rubber provides unmatched flexibility and foam tends to offer the best compression set, plastic gaskets are used for applications requiring excellent tensile and flexural strength.
Plastic is often more lightweight than other gasketing materials, which makes it ideal for applications where weight is a concern. Compared to more specialized materials, plastic tends to be more cost-effective.
With resistance to chemicals and oils, as well as non-contaminating properties, plastic gaskets are commonly used in the food and beverage industry where components need to meet FDA standards.
Here is a comparison of common plastic gasket materials:
Product |
Temp Range |
Benefits |
Common Uses |
| Nylon Gaskets | -70°F to 250°F (-57°C to 121°C) | Resistance to gasoline, oils, and chemicals; low permeability and high abrasion resistance. | Plumbing, automotive, electronics, and hydraulic applications. |
| Polytetrafluoroethylene (PTFE) Gaskets | -103°F to 500°F (-75°C to +260°C) | Superior resistance to acids, bases, and solvents; electrical insulation and non-contaminating properties. | Food processing, pharmaceutical manufacturing, and chemical processing. |
| Polyethelene (PE) Gaskets | HDPE: -58°F to 176°F (-50°C to 80°C)
LDPE: -58°F to 149°F (-50°C to 65°C) |
Chemical and moisture resistance; lightweight and more cost-effective than similar gaskets. | Automotive, HVAC, food processing, and medical equipment. |
Custom Gasket Fabrication is the Answer
Each industrial application has unique specifications to meet. With so many different factors, custom fabrication is the best way to create a perfect seal for your equipment. Off-the-shelf gaskets come in generic sizes and are made from materials that don’t offer specialized properties.
For gaskets that meet your exact requirements, trust American Flexible Products for custom fabrication. With more than 30 years of industry expertise, we can make gaskets that fit even the most precise specifications.
Contact us today to discuss your project or receive a custom quote. As a 100% employee-owned company, you’ll speak to an owner every time you reach out.
