Rubber to Metal Bonded Seals

These are composite sealing components in which elastomer materials are chemically and mechanically bonded to a metal insert or substrate. This combination leverages the flexibility and sealing properties of rubber with the strength and dimensional stability of metal – ideal for dynamic, high-pressure, or structurally integrated applications.

Rubber to metal bonded seals deliver structural rigidity where needed while maintaining a resilient sealing interface. They resist extrusion, improve installation reliability, and maintain sealing integrity in high-load, high-vibration, or high-pressure environments – where purely rubber seals may deform or fail.

We provide bonded seals to OEMs in waterworks, irrigation, aerospace/military, medical/life sciences, chemical processing, oil and gas, semiconductor manufacturing and food processing. In these industries, joint reliability and performance under extreme conditions are mission-critical.

We work with a range of metal substrates such as stainless steel, aluminum, brass, and carbon steel. These are paired with elastomers like NBR, FKM, EPDM, HNBR, and Silicone – selected to match the application’s chemical, thermal, and mechanical demands. The bonding process is engineered to ensure consistent adhesion and long-term durability.

We use a proven process involving surface preparation (e.g., grit blasting), chemical primers, and compression or injection molding. The elastomer is cured directly onto the metal insert, creating a chemical and mechanical bond that withstands pressure cycling, thermal expansion, and vibration.

These seals are used in hydraulic and pneumatic systems, pressure vessels, fuel and fluid handling systems, automotive mounts, valve assemblies, medical devices, and instrumentation. If you need integrated sealing with mechanical support or vibration isolation, bonded seals are often the best solution.

Absolutely. Bonded seals are ideal for applications involving repeated pressure cycles, mechanical movement, or temperature fluctuations. The elastomer absorbs shock and compensates for tolerance stack-ups, while the metal provides stable anchoring.

Yes. We manufacture in compliance with industry standards such as FDA, USP Class VI, MIL-SPEC, ISO 9001, and others depending on the target application. Traceability, material certifications, and validation testing are available on request.

We do. Whether you’re developing a new component, testing a concept, or validating a pre-production model, we support prototyping with short lead times and flexible tooling options. Scale-up is seamless once the design is finalized.

Properly designed and specified, our bonded seals can last for millions of cycles or years of continuous use, even under harsh operating conditions. We factor in temperature cycling, media compatibility, and load profiles to optimize longevity. However, lifespan must be tested by customers and might be shorter in a very aggressive environment.

Just share your design files, performance requirements, or even a problematic component. Our team will assess your needs and propose a complete solution—material pairing, geometry, bonding process, and production plan. You’ll get a seal that performs exactly as intended in your real-world application.

Compression set indicates the permanent deformation of an O-ring after compression and release, affecting its ability to maintain a seal. A high compression set suggests material fatigue and reduced sealing effectiveness, which can lead to leaks. However, compression set alone does not directly determine an O-ring’s lifespan.

Key Factors Influencing O-Ring Lifespan:

• Environmental Conditions: Elevated temperatures and chemical exposure can accelerate material degradation, increasing compression set and reducing lifespan.
• Material Properties: Different rubber materials (e.g., Nitrile, EPDM, FKM, Silicone, etc.) have varying resistance to compression set and aging factors such as ozone, UV light, oils, chemicals etc.
• Operational Factors: The level of compression and whether the O-ring is in a static or dynamic application impact its performance. Excessive compression or dynamic movement can lead to a higher compression set.
• Design and Installation: Proper sizing and correct installation are crucial. Incorrect installation or poorly designed glands can cause excessive compression, leading to higher compression set.

To estimate an O-ring’s lifespan, compression set should be evaluated alongside environmental conditions, material properties, and operational factors. Accelerated aging tests and real-world performance data provide insights into how compression set affects lifespan. Regular monitoring and inspection of O-rings in service help predict and extend their useful life, ensuring reliable sealing performance. This holistic assessment allows for more accurate lifespan predictions and proactive maintenance strategies.