Table Of Contents
Key Points
- Different processes like die cutting, extruding, molding, and form-in-place (FIP) methods are best suited for specific gasket manufacturing scenarios, impacting quality, cost, and timeline.
- Material choice for an electrically conductive gasket is vital, affecting performance, durability, and environmental resistance.
- A knowledgeable manufacturer like Modus Advanced Inc. can guide process and material selection, which can reduce cost and risk.
When it comes to manufacturing an electrically conductive gasket, choosing the right manufacturing process is crucial. A failed device in the field can have serious consequences, not only for your end user, but for your business as well. You need a partner who understands your needs, can provide a thorough design for manufacturability review, and can help bring your concept to reality.
In this blog post, we will guide you through the process of selecting the ideal manufacturing process for your electrically conductive gasket. Whether you're considering die cutting, extruded gaskets, molded gaskets, or form-in-place (FIP) gaskets, we'll provide valuable insights to help you make an informed decision.
Here at Modus Advanced, we offer a wide variety of manufacturing processes all under one roof to meet the needs of our partners. If you’re unsure of what process is a best fit for your electrically conductive gasket project, reach out and speak with our engineering team today.
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Learn everything you need to know about EMI gasket design!
Die Cutting: The Right Fit for Your Custom Gasket?
Die cutting is a widely used method for manufacturing custom gaskets. It involves precisely cutting materials into specific shapes using a die. There are several types of dies to choose from including steel rule dies, solid milled dies, and male/female or compound dies to cut or punch sheets of gasket material. Steel rule dies are typically the least expensive and can offer a faster turnaround time than other types of dies.
Depending on the materials involved and the type of die needed, it may be a good fit for the following scenarios:
- You need high-volume parts
- The part isn’t too large or too small
- The part doesn’t have narrow walls
- The material being cut isn’t too thick
- You have a lead time of over a week
By utilizing die cutting, you can achieve the desired shape and dimensions for your electrically conductive gasket, ensuring a precise fit for your application.
If you’re looking for more in-depth information on die cutting, check our full blog post on the topic: Is Die Cutting the Right Fit for Your Custom Gasket?
Extruded Gaskets: For Standard and Semi-Standard Profiles
An extruded gasket is a flexible gasket that has an internal profile in a specific shape that is meant to fit your design. The ends are bonded together to create a closed system and then applied to your design. It can be an excellent choice for creating gaskets with standard or semi-standard profiles.
This process is particularly effective for electrically conductive gaskets that require shapes such as solid O, hollow O, D, P, E, U, solid square, and square hollow profiles. It's ideal for:
- Flange and groove applications
- Achieving specific lengths or continuous lengths
- High-volume production requirements
- The need for splice or bond to meet specific requirements
More details about the advantages and applications of extruded gaskets can be found in our blog post: The Top 4 EMI Shielding Gasket Manufacturing Processes.
Molded Gaskets: For Customized Precision
Molded gaskets offer an incredible level of customization. They are manufactured using a mold and can conform perfectly to your design requirements. This process is ideal for:
- Eliminating waste typically associated with the die-cut process
- Creating three-dimensional designs
- Complex designs requiring precision and high tolerances
However, molded gaskets involve higher tooling costs and longer lead times. Because of this, it's necessary to factor these considerations into your decision-making process.
For a more comprehensive look at molded gaskets, take a look at our blog post on The Top 4 EMI Shielding Gasket Manufacturing Processes.
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Form-in-Place (FIP) Gaskets: Precision, Flexibility, and Space Optimization
FIP gaskets are used to create environmental seals and oftentimes are used to create electromagnetic interference (EMI) shields. They offer a unique combination of precision, flexibility, and space optimization. If you’re in the aerospace and defense, medical device, or emerging technology industries, you’ve surely come across an FIP gasket a time or two.
In this process, the electrically conductive silicone is CNC dispensed directly onto the substrate as a precise bead. Its simple application reduces material waste significantly and reduces cost. It may be a good choice for the following situations:
- Lower compression force is desired
- Fast assembly or short turnaround time is required
- Small, complex, and intricate designs
- Excellent shielding properties are required
- Situations where installation of the gasket is very difficult, or would be made easier if the gasket were adhered to the part surface
From satellites and medical devices to radar systems, FIP gaskets are everywhere.
To learn more about FIP gaskets and choosing the right dispensing partner, read our blog post on Form-in-Place Gasket Services: What to Look for in a Manufacturing Partner.
The Importance of Material Selection
Apart from choosing the right manufacturing process, it's also essential to select the right materials for your electrically conductive gasket. The material used will directly impact the gasket's performance and longevity. Factors such as temperature, pressure, chemical resistance, and electrical conductivity are crucial considerations.
At Modus Advanced Inc., we offer a variety of materials for electrically conductive gaskets, including but not limited to, silicone, fluorosilicone, and EPDM, each available with a range of conductive fillers. There are literally thousands of materials to choose from, so we’ve crafted a list of 27 of the most common to get you started – read it here. Our expert engineers will guide you through the selection process to ensure your gasket provides optimum performance in its application environment.
Over the years, we’ve found that there are 10 key questions you can ask yourself when you’re choosing a material for your custom gasket. They include questions such as “Will the gasket be used indoors or outdoors?” and “Is outgassing a concern?” among several others. These 10 questions are a great place to start, but if you’re short on time and want to get to the answer quick, reach out and speak with our engineers today.
The Final Decision
Ultimately, the decision for the right manufacturing process will depend on your specific design requirements, budget, lead times, and the specific properties required of your electrically conductive gasket. At Modus Advanced Inc., we offer a robust Design for Manufacturability review to guide you in making this critical decision.
Remember, the choice of the manufacturing process is not just about the present project requirements, but it should also take into account future needs. A manufacturing partner like Modus Advanced Inc., with a diverse range of capabilities and a commitment to quality, can help streamline the manufacturing process, reduce risks, and ensure long-term success.
Ready to design the perfect gasket? Contact us today to get started!
