As industries evolve toward smarter, smaller, and more connected technologies, enclosures are facing new challenges. Design engineers are under pressure to deliver lighter, thinner, and safer enclosures that protect sensitive electronics from harsh environments while still meeting demanding performance standards.
This shift is transforming how gaskets and seals are designed and what materials are being used across key markets such as electric vehicles (EVs), medical devices, energy storage systems (ESS), and data centers.
Check out the extended blog on the Rogers website, The Future of Sealing: How Tomorrow's Applications Are Changing, and the video below to see where enclosures are heading and what will be necessary by the teams designing these enclosures.
*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.
1. Shrinking Designs, Bigger Demands
Devices today are becoming increasingly compact. In EV battery assemblies, wearable medical devices, and high-density data centers, every millimeter counts. Enclosure walls are being designed thinner to reduce weight and size, which means engineers can no longer rely on rigid seals or thick gaskets to achieve proper compression and environmental protection.
In electric vehicles, minimizing weight is especially critical for maximizing range. The AAA Automotive Engineering Research Team, for example, found that the range of a Ford F-150 Lightning dropped by 24.5% when carrying heavy cargo, highlighting how even modest increases in mass can significantly affect vehicle efficiency (AAA, 2022).
Designing for these smaller, thinner, and lighter assemblies requires materials that compress easily, maintain sealing integrity under lower closure forces, and provide consistent long-term performance.
2. Softer Gaskets for Reliable Sealing in Modern Designs
As components, housings, and walls become thinner and more delicate, enclosure forces decrease, making softer gaskets and seals more essential than ever.
Materials such as open-cell polyurethane and silicone foam conform to irregular surfaces, accommodate manufacturing tolerances, and maintain reliable sealing performance while reducing stress on the enclosure.
3. Venting for High-Performance Enclosures
As highlighted in our recent blog on enclosure venting, effective venting ensures a safe balance between internal and external pressure. Without proper venting, pressure fluctuations caused by temperature changes, altitude shifts, or gas generation can lead to seal failure or even structural damage.
In EV battery packs and energy storage systems (ESS), pressure relief vents are essential for managing off-gassing events while maintaining protection against moisture and particulates. In data centers, venting supports airflow balance and thermal management within densely packed electronics. Medical devices also benefit from vented enclosures that equalize pressure without compromising sterility or patient safety.
The key is selecting venting materials and adhesive-backed films that provide controlled airflow while blocking contaminants. Engineers often combine these with precision-cut foam or elastomeric seals to achieve the right balance of protection, performance, and reliability.
4. Increased Standards for Flammability, Safety, and Global Compliance
Evolving markets and designs are also driving stricter compliance requirements. EV battery assemblies and energy storage systems must meet UL 94 V-0 flammability ratings and other global safety standards to minimize fire risk. Similarly, medical devices are regulated under ISO 10993 for biocompatibility, while data center components often need to meet smoke and toxicity requirements.
Material selection plays a vital role in meeting these standards. Flame-retardant silicones, polyurethanes, and fluorosilicones can offer excellent compression set resistance and high-temperature performance while satisfying regulatory demands. Working closely with material suppliers like Rogers Corporation that understand these certifications can accelerate development and ensure long-term compliance.
5. Sensor Integration for a Connected World
The rapid growth of the Internet of Things (IoT) is increasing the need for reliable, connected devices across markets like, automotive, medical, and industrial, and appliances. As sensors and circuits become smaller and more integrated, engineers must design gaskets that protect IoT device enclosures from dust, moisture, and vibration while preserving signal integrity.
Materials that absorb shock, reduce noise, and prevent electromagnetic interference (EMI), such as conductive gaskets and EMI shielding foams, help ensure accurate sensor performance and dependable wireless communication in compact, high-performance IoT applications.
6. Thermal Management and Environmental Sealing for Extreme Conditions
As technology advances, enclosures must perform reliably in increasingly harsh and demanding conditions. Outdoor systems such as EV chargers, solar inverters, and remote monitoring equipment face exposure to wide temperature ranges, moisture, UV light, and chemicals, while compact electronics in EVs, data centers, and energy storage units generate more heat in smaller spaces.
Engineers are addressing both challenges through materials that provide environmental resilience and thermal control. Silicone gaskets maintain flexibility and sealing integrity in extreme climates, while thermally conductive gap fillers, pads, and phase-change materials help dissipate heat and protect sensitive components, ensuring long-term reliability and performance.
Key Takeaways: Designing Gaskets for the Next Generation of Technology
Emerging technologies are reshaping how engineers think about enclosure design and sealing materials. Devices are being designed thinner, smarter, and more connected, but that brings new challenges in pressure management, thermal control, compliance, and reliability.
To stay ahead, design engineers should:
- Use softer, low-compression materials to protect thinner enclosures
- Integrate venting solutions to balance pressure safely
- Select materials that meet flammability, biocompatibility, and EMI standards
- Choose gaskets resilient to temperature and environmental extremes
- Incorporate thermal management into sealing strategies
Engineers who plan for these factors now will lead the next wave of innovation, one perfectly sealed enclosure at a time.
Read the extended blog on Rogers’ website here.
Sign up for the Enclosure Institute™ for more exclusive content like this (and more) and be the first to know when new content goes live.
Enroll in The Enclosure Institute™ today!
NOW That's What I Call Enclosure Sealing!
Checkout some of the greatest hits from the Enclosure Institute™
- NEMA, UL, CSA, & IEC Ratings Explained for Enclosures
- How to Prevent Gasket Failure - Part 1
- 8 Critical Factors That Influence Seal and Gasket Functionality
- A Practical Guide to Gasket Material Selection
- 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.
