Selecting the right fabrication process for custom seals and gaskets starts with answering a few critical design-for-manufacturing (DFM) questions. By addressing these factors upfront, design engineers can avoid costly redesigns, speed up production, and ensure that their parts meet application requirements. At Marian, our engineers use these questions (and more) to create a fabrication plan tailored to each project.
This guide is presented by the Enclosure Institute™. For a deeper dive, explore the extended blog on the Rogers website, Top 8 Best Practices You Need to Know for Enclosure Die-Cut Gaskets, along with the video below hosted by Marian's own Phil Taylor and Jimmy Budd.
In these resources, you'll learn how starting with the right gasket design can optimize geometry to balance sealing force, fasteners, and load distribution. You'll also see why selecting manufacturing methods that align with production scale is critical for efficiency. Assembly features such as pull-tabs, locating holes, and specialized adhesives help streamline installation and minimize errors. Finally, packaging and delivery strategies play an often-overlooked role in protecting gasket integrity while making assembly faster and more reliable.
*Disclaimer: The Enclosure Institute™ is a free educational resource created by Marian, Inc. and Rogers Corporation to help engineers navigate enclosure sealing with expert guidance.
Gasket Fabrication Considerations for Success
What is the required production volume?
One of the first considerations is production volume. Do you need just a few prototypes for testing or millions of finished parts? Prototyping typically calls for a process with minimal setup and no tooling, while high-volume production may justify custom tooling to increase efficiency and consistency.
What material is to be cut?
Material properties are another essential factor. The hardness, thickness, number of layers, and overall composition of the chosen material all influence which processes can be used. It's also important to be aware of the material format, meaning knowing if the material is provided in sheets, rolls, or other formats. Engineers must also decide if the design calls for a single-piece gasket or multiple parts layered together.
What is the precision needed?
Precision requirements directly affect which fabrication methods are feasible. If your design demands tight tolerances or has critical dimensions that must be held within narrow limits, those details must be identified early. This allows the engineering team to select cutting methods that can achieve the necessary accuracy while balancing cost and throughput.
How do the parts need to be packaged for delivery?
Packaging and delivery are often overlooked but play an important role in downstream efficiency. Should parts be shipped loose in a box, kiss-cut on rolls, or supplied as individual pads? The right packaging method can simplify handling, storage, and application for both you and your customer.
How will the parts be applied?
Application methods also influence design. If parts are applied by hand, features like pull-tabs, extended liners, or stiffeners may be added to make handling easier. For automated applications, parts must be optimized for feeding and placement consistency.
What is the adhesive wet out method?
Finally, adhesive requirements must be carefully planned. If adhesive is needed, engineers will determine the best way to laminate it to the part and ensure proper adhesion to the intended enclosure.
By working through these considerations including volume, material, precision, packaging, application, and adhesive, engineers can streamline the fabrication process and ensure that custom gaskets and seals perform reliably in real-world applications.
The bottom line: reliable enclosure performance depends on more than just choosing the right material. By integrating thoughtful design, manufacturability, installation ease, and protective packaging, engineers can ensure their gaskets deliver lasting protection.
Read the extended blog on Rogers’ website here.
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Coming Up Next in Module 4 of the Enclosure Institute™
- Die-cut foam gaskets vs. Form-in-place solutions
- Venting Considerations for Gasket Design
- Future Sealing Design Trends
- And much more!
Working on an enclosure application and not sure where to start or currently knee-deep in an active project and not sure what's next? Contact us and we'll put you in touch with a Sales Engineer in your area. Our technical teams can walk you through all the important considerations to make sure your application is ready to go to market without issues.
