• Do you know you could be paying your gasket converter to throw away up to 75 percent of the material used to make your gasket? Don’t make the mistake of assuming a die cut gasket is the optimal solution!
• Consider a custom molded rubber gasket if your gasket design will result in substantial material waste. A custom molded gasket can lead to substantially lower costs, especially if it’s a nickel graphite or silver filled EMI shielding gasket.
• Would an extruded and spliced gasket be a better solution for large, irregular shaped sealing surfaces? Extrusion profiles can be optimized for lower compression force, potentially resulting in a better seal and reduction in the number of fasteners.
• Form in place gaskets can not only provide cost reduction opportunities, but also performance advantages as well. A dispensed FIP gasket can also lead to fewer assembly issues when dealing with thin gasket walls.
The Real World:
• We were lucky enough to have one of our customers introduce us to form in place gaskets years ago. Seven gasket dispensing machines later, we’re well on our way to being the largest contract FIP gasket manufacturer on our street. The customer could clearly see the raw material savings advantages to dispensing an FIP gasket on their housing. We were able to cut the cost of their die cut EMI shielding gasket in half by using an alternative gasket manufacturing method.
• A different customer asked us to manufacture a large EMI shielding frame gasket, with PSA on one side. In order to meet their price target, we knew we couldn’t simply die cut the gaskets from sheet material. We decided the best alternative was to first mold a picture frame, second apply an electrically conductive PSA and finally die cut the gasket from the PSA backed frame. When working with expensive materials like electrically conductive silicones, it makes sense to consider alternative manufacturing methods. This solution is still saving the customer over $10,000 per year in gasket costs.