1. Define Application Requirements

• Operating Environment:

  • Temperature range (min/max).

  • Exposure to chemicals, oils, UV, ozone, or moisture.

  • Pressure/vacuum conditions.

• Function:

  • Sealing (static/dynamic), vibration damping, insulation, etc.

• Regulatory Standards:

  • Compliance with industry standards (e.g., FDA, ASTM, ISO).

2. Material Selection

1. Pure Rubber

   • Applications:

     • Low to moderate pressure (<10 MPa).

     • Moderate temperatures (within the rubber’s rated range, e.g., -50°C to 150°C for EPDM).

     • Flexible installation (e.g., compressible for uneven surfaces).

   • Advantages:

     • Cost-effective, lightweight, and easy to mold into complex shapes.

2. Composite Materials

   • Plastic-Rubber Laminates:

     • Use Case:

       • Chemical resistance + dimensional stability (e.g., PTFE-backed rubber for aggressive media).

       • Low friction surfaces (PTFE layer reduces stick-slip in dynamic seals).

     • Pressure/Temperature: Suitable for moderate pressure (5–20 MPa) and high temps (up to 200°C with PTFE).

   • Metal-Rubber Hybrids (e.g., Metal-Cored or Armored Gaskets):

     • Use Case:

       • High-pressure systems (>20 MPa) requiring anti-extrusion.

       • Extreme temperatures (metal core prevents thermal distortion).

       • Critical installations requiring rigidity (e.g., bolted flanges in pipelines).

     • Design Tips:

       • Embed metal rings/spirals in rubber to prevent blowout under cyclic pressure.

       • Use stainless steel or aluminum cores for corrosion-prone environments.

3. Gasket Geometry Design

• Cross-Section Profile:

  Design according to the assembly groove. 

• Dimensions:

  Compression ratio: 15–30% (prevents over-stress or leakage).