The Technical Hub
O-Ring Calculator
This interactive calculator assists engineers with selection of O-ring and hardware dimensions, and to form the basis of an O-ring installation.
Chemical Compatibility Checker
This interactive guide will help you choose a seal material based on existing compatibility test results of known chemicals and elastomers.
Interactive Engineering Calculators
Click here for volume, mass and compression set values for O-rings and rotary seal and hydraulic cylinder calculations.
Unit Converter
Our interactive conversion tools allow engineers to switch between units of measurement when preparing engineering calculations.
Engineering Tables
Our reference tables provide cross reference information for surface finish, metal hardness and polymer hardness measurement units.
Rotary seals for heavy duty transportationSupply Plus Ltd designs, manufactures, supplies and distributes safety and fuel delivery equipment, with brands including AS Fire & Safety, Bayley and Collins Youldon. The application Our customer, Supply Plus approached us with a requirement for their 2” Swing joint power spindle. The outlet pipe from the fuel tank on delivery vehicles is fed into the centre of a rotating hose reel. This is located between the tank and cab of the vehicle. This is powered by an electric motor and pumped through at relatively low pressure. The current design experienced issues of leakage from the hose fitting in low temperatures especially at -25°C, and particularly when vehicles are parked overnight. Therefore we recommended a rotary seal for this heavy duty transportation. The challenges This application required a rotary seal with low temperature capability and excellent resistance to oil-based fuels. A design was required to replace the existing seal in the available housing between the rotating metal faces. Therefore a standard spring energised rotary seal would not work in the application; a bespoke design was required. Leakage at night when vehicles are not in use often means the issue worsens because the seal is cold and not energised. Therefore, we designed a rotary seal for heavy duty transportation that would remain energised at low temperatures and low pressure. Our sealing solution Our engineers designed a simple but effective seal, incorporating a large heel in the base of the housing. This energised a lip sealing on a rotating metal face. The volume of rubber in the heel of the seal, combined with the 170° angled base, created sufficient force to maintain a seal at low pressure. We used a low temperature Viton ensuring the seal retained elastomeric properties and applied the sealing force at low energising pressures and very low temperatures. This also provided excellent resistance to fuel oils, diesel and aviation fuel. We tested prototypes at both an in-house test unit and in the field over four winter months. Results showed no issues during dispense of fuel and a complete cessation of leakage. The seal was approved and production orders placed, and the design has been incorporated across additional sizes of hose reels. Learn more about our rotary seals HERE
Moulded gaskets for an automotive applicationAn existing customer (an automotive manufacturer) approached our engineers with an application where they were experiencing failures of a seal designed and manufactured by another rubber seal provider.
The application
This moulded gasket is used within a valve housing in an automotive application. The competitor gasket experienced failure at the “T-junction” areas of the seal. Our customer had experienced chronic failures of their existing moulded gasket design at high temperatures and high pressures. The seal is required to perform under pulsating pressure of up to 50 Bar and temperatures of up to 150°C. Our engineers reviewed the existing gasket design and application conditions and recommended an increase in height of 0.40 mm. This was to increase the compression and improve the sealing function. Additional beads were also added to further stabilise the gasket in the groove.
The challenges
Prototype parts were manufactured from a single cavity soft tool and sent to the customer for in-house testing and validation. The prototype gaskets very nearly passed testing but did not quite reach the 50 Bar pressure requirement at 150° C (42 Bar reached). This was still a great improvement on the performance of the customer’s original gasket. Analysis of the customers test data and images of the tested parts, determined there were areas where the gasket was sliding in the groove and then shearing as the pressure pulsed. We resolved this issue by our engineers adding beads to the rear of the T-intersections of the gasket. This provided additional support and further stabilised the gasket at the high-pressure stress points in the groove, and reduced movement within the housing. The number of additional beads added needed to be balanced carefully with calculations on groove fill. Further development captured the cleanliness requirements and altered radii on the beads.
Customer satisfaction
The new design was approved, and the customer moved to production tooling stage and sample parts were produced to PPAP Level 3 for production. More information about our mouldings & gaskets on the link HERE
Special O-rings for an automotive applicationOur customer manufactures high performance oil and vacuum pump solutions, and approached our engineers with a new O-ring application for review.
The application
Our customer required an FKM (Viton™) 60 shore special O-ring. This is to meet Porsche material specification PN707 Class 2 (Oil), Class 5 (Fuel/FAME mix) and Class 12 (Blowby gas). This proved to be a very cost sensitive project with a short lead time. Additionally, we did not have an existing grade in our materials portfolio to meet this specialised O-ring specification.
The challenges
Our engineers reviewed the application and we provided two material options. The first is a lower cost grade of FKM (Viton™) A grade, and would possibly meet the Porsche specification required. The second material, a medium to higher cost FKM (Viton™) B grade that will definitely meet the specification. We supplied a quotation for the two material types. Additionally, the quotation included production tooling, PPAP Level 3 submission, testing for both materials and a pre-production batch of O-rings. The project was urgent and we were able to accommodate PPAP Level 3 grade O-rings for both materials to be manufactured from the same tool. Also, to save time we conducted material testing in tandem with the manufacture and preparation of the the production tool. The choice of compound to be used in the tool would be made on review of the results of material testing. On completion of the material testing, the customer reviewed the results with Porsche. The decision to produce O-rings from the FKM B grade was made.
Customer satisfaction
By this stage of testing, production tooling was complete, allowing manufacture of PPAP 3 samples and the pre-production batch to commence. Pre-production O-rings were supplied to the customer in the promised 12-week lead time together with PPAP Level 3 and PPAP 3 samples. See this link for more on our O-ring range and expertise: HERE
High speed Rotary seals for electric vehiclesThe electric vehicle industry is growing; global manufacturing and registrations of electric vehicles is increasing exponentially each year. Our engineers have extensive experience in designing seals for automotive applications, but we still find new challenges involved in sealing components within hybrid, hydrogen fuel and full battery powered electric vehicles.
Why use PTFE seals?Polytetrafluoroethylene (PTFE) is a thermoplastic polymer that can be used in a variety of sealing applications; it is particularly suitable where the application conditions exceed the parameters of elastomeric seal use, but are not as highly demanding as applications that require the use of metal seals.
Why use metal seals?The use of metal seals as an engineered sealing solution is appropriate where it is not possible to use elastomeric or polymer seals due to extremely demanding application requirements. For example, these could include applications with extremely high temperatures (300°C upwards) and pressures, intense radiation, cryogenic conditions or highly aggressive chemicals.
Why use Push-in-Place gaskets?Where a seal groove follows an irregular path or profile, a common sealing solution is to design a custom Push-In-Place (PIP) gasket that has the same profile as the centre line of the groove, simply drops into place and is retained by the features of its own design.
Seals for electric vehiclesPropelled by one or more electric motors and using energy stored in rechargeable batteries, electric vehicles are quieter, have zero exhaust emissions and lower emissions in general compared to internal combustion engines. The number of electric vehicles on the road grows exponentially every year globally, and our engineers support manufacturers with innovative sealing solutions in these specialist areas of application.
3D printing for seals3D printing has developed significantly and now performs a crucial role in many applications. 3D printed products vary from fully functional to purely aesthetic applications; with the most common application being for manufacturing. Here we discuss how our engineers use 3D printing to demonstrate a seal concept.
O-rings with special coatingsAll seals require some form of installation into application hardware and often this may seem to be a simple push in place function. However, without consideration of certain conditions this can potentially create sealing problems further into the life cycle of the seal. Once installation is achieved a seal can often sit in the housing hardware for many months...which potentially allows it to stick to the housing material and cause further issues. This is where special coatings can make a difference.
Tools
O-Ring Calculator
This interactive calculator assists engineers with selection of O-ring and hardware dimensions, and to form the basis of an O-ring installation.
Chemical Compatibility Checker
This interactive guide will help you choose a seal material based on existing compatibility test results of known chemicals and elastomers.
Interactive Engineering Calculators
Click here for volume, mass and compression set values for O-rings and rotary seal and hydraulic cylinder calculations.
Unit Converter
Our interactive conversion tools allow engineers to switch between units of measurement when preparing engineering calculations.
Engineering Tables
Our reference tables provide cross reference information for surface finish, metal hardness and polymer hardness measurement units.
Articles
Rotary seals for heavy duty transportationSupply Plus Ltd designs, manufactures, supplies and distributes safety and fuel delivery equipment, with brands including AS Fire & Safety, Bayley and Collins Youldon. The application Our customer, Supply Plus approached us with a requirement for their 2” Swing joint power spindle. The outlet pipe from the fuel tank on delivery vehicles is fed into the centre of a rotating hose reel. This is located between the tank and cab of the vehicle. This is powered by an electric motor and pumped through at relatively low pressure. The current design experienced issues of leakage from the hose fitting in low temperatures especially at -25°C, and particularly when vehicles are parked overnight. Therefore we recommended a rotary seal for this heavy duty transportation. The challenges This application required a rotary seal with low temperature capability and excellent resistance to oil-based fuels. A design was required to replace the existing seal in the available housing between the rotating metal faces. Therefore a standard spring energised rotary seal would not work in the application; a bespoke design was required. Leakage at night when vehicles are not in use often means the issue worsens because the seal is cold and not energised. Therefore, we designed a rotary seal for heavy duty transportation that would remain energised at low temperatures and low pressure. Our sealing solution Our engineers designed a simple but effective seal, incorporating a large heel in the base of the housing. This energised a lip sealing on a rotating metal face. The volume of rubber in the heel of the seal, combined with the 170° angled base, created sufficient force to maintain a seal at low pressure. We used a low temperature Viton ensuring the seal retained elastomeric properties and applied the sealing force at low energising pressures and very low temperatures. This also provided excellent resistance to fuel oils, diesel and aviation fuel. We tested prototypes at both an in-house test unit and in the field over four winter months. Results showed no issues during dispense of fuel and a complete cessation of leakage. The seal was approved and production orders placed, and the design has been incorporated across additional sizes of hose reels. Learn more about our rotary seals HERE
Moulded gaskets for an automotive applicationAn existing customer (an automotive manufacturer) approached our engineers with an application where they were experiencing failures of a seal designed and manufactured by another rubber seal provider.
The application
This moulded gasket is used within a valve housing in an automotive application. The competitor gasket experienced failure at the “T-junction” areas of the seal. Our customer had experienced chronic failures of their existing moulded gasket design at high temperatures and high pressures. The seal is required to perform under pulsating pressure of up to 50 Bar and temperatures of up to 150°C. Our engineers reviewed the existing gasket design and application conditions and recommended an increase in height of 0.40 mm. This was to increase the compression and improve the sealing function. Additional beads were also added to further stabilise the gasket in the groove.
The challenges
Prototype parts were manufactured from a single cavity soft tool and sent to the customer for in-house testing and validation. The prototype gaskets very nearly passed testing but did not quite reach the 50 Bar pressure requirement at 150° C (42 Bar reached). This was still a great improvement on the performance of the customer’s original gasket. Analysis of the customers test data and images of the tested parts, determined there were areas where the gasket was sliding in the groove and then shearing as the pressure pulsed. We resolved this issue by our engineers adding beads to the rear of the T-intersections of the gasket. This provided additional support and further stabilised the gasket at the high-pressure stress points in the groove, and reduced movement within the housing. The number of additional beads added needed to be balanced carefully with calculations on groove fill. Further development captured the cleanliness requirements and altered radii on the beads.
Customer satisfaction
The new design was approved, and the customer moved to production tooling stage and sample parts were produced to PPAP Level 3 for production. More information about our mouldings & gaskets on the link HERE
Special O-rings for an automotive applicationOur customer manufactures high performance oil and vacuum pump solutions, and approached our engineers with a new O-ring application for review.
The application
Our customer required an FKM (Viton™) 60 shore special O-ring. This is to meet Porsche material specification PN707 Class 2 (Oil), Class 5 (Fuel/FAME mix) and Class 12 (Blowby gas). This proved to be a very cost sensitive project with a short lead time. Additionally, we did not have an existing grade in our materials portfolio to meet this specialised O-ring specification.
The challenges
Our engineers reviewed the application and we provided two material options. The first is a lower cost grade of FKM (Viton™) A grade, and would possibly meet the Porsche specification required. The second material, a medium to higher cost FKM (Viton™) B grade that will definitely meet the specification. We supplied a quotation for the two material types. Additionally, the quotation included production tooling, PPAP Level 3 submission, testing for both materials and a pre-production batch of O-rings. The project was urgent and we were able to accommodate PPAP Level 3 grade O-rings for both materials to be manufactured from the same tool. Also, to save time we conducted material testing in tandem with the manufacture and preparation of the the production tool. The choice of compound to be used in the tool would be made on review of the results of material testing. On completion of the material testing, the customer reviewed the results with Porsche. The decision to produce O-rings from the FKM B grade was made.
Customer satisfaction
By this stage of testing, production tooling was complete, allowing manufacture of PPAP 3 samples and the pre-production batch to commence. Pre-production O-rings were supplied to the customer in the promised 12-week lead time together with PPAP Level 3 and PPAP 3 samples. See this link for more on our O-ring range and expertise: HERE
High speed Rotary seals for electric vehiclesThe electric vehicle industry is growing; global manufacturing and registrations of electric vehicles is increasing exponentially each year. Our engineers have extensive experience in designing seals for automotive applications, but we still find new challenges involved in sealing components within hybrid, hydrogen fuel and full battery powered electric vehicles.
Why use PTFE seals?Polytetrafluoroethylene (PTFE) is a thermoplastic polymer that can be used in a variety of sealing applications; it is particularly suitable where the application conditions exceed the parameters of elastomeric seal use, but are not as highly demanding as applications that require the use of metal seals.
Why use metal seals?The use of metal seals as an engineered sealing solution is appropriate where it is not possible to use elastomeric or polymer seals due to extremely demanding application requirements. For example, these could include applications with extremely high temperatures (300°C upwards) and pressures, intense radiation, cryogenic conditions or highly aggressive chemicals.
Why use Push-in-Place gaskets?Where a seal groove follows an irregular path or profile, a common sealing solution is to design a custom Push-In-Place (PIP) gasket that has the same profile as the centre line of the groove, simply drops into place and is retained by the features of its own design.
Seals for electric vehiclesPropelled by one or more electric motors and using energy stored in rechargeable batteries, electric vehicles are quieter, have zero exhaust emissions and lower emissions in general compared to internal combustion engines. The number of electric vehicles on the road grows exponentially every year globally, and our engineers support manufacturers with innovative sealing solutions in these specialist areas of application.
3D printing for seals3D printing has developed significantly and now performs a crucial role in many applications. 3D printed products vary from fully functional to purely aesthetic applications; with the most common application being for manufacturing. Here we discuss how our engineers use 3D printing to demonstrate a seal concept.
O-rings with special coatingsAll seals require some form of installation into application hardware and often this may seem to be a simple push in place function. However, without consideration of certain conditions this can potentially create sealing problems further into the life cycle of the seal. Once installation is achieved a seal can often sit in the housing hardware for many months...which potentially allows it to stick to the housing material and cause further issues. This is where special coatings can make a difference.
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Product Range
Our seal products range from simple static O-rings to complex and bespoke seal designs in specialist materials. Whatever your application, we have the seal product for you.
