A case study from a US-based sealing distributer highlights the causes of elastomer gasket failures and the collaboration, reverse engineering and smart material selection that can prevent them
Randi Claire Villeda-Lindsay discusses how smart material engineering can solve elastomer gasket failures
In complex mechanical systems – especially those in the automotive sector – seemingly minor components can cause major problems when they fail. Elastomer gaskets, for example, play a vital role in sealing fluid systems, yet they’re often overlooked until something goes wrong.
A recent case study from a US-based sealing distributor highlights how unexpected chemical incompatibility can disrupt performance, and how collaboration, reverse engineering, and smart material selection can provide a long-term solution for OEMs facing similar challenges.
THE PROBLEM
According to the case study, a long-term client in the transportation industry began experiencing premature failures in a custom-moulded elastomer gasket. The gaskets were part of a mobile unit’s cooling system and had been performing reliably until failures started surfacing in the field, leading to leaks, downtime, and costly warranty claims.
The issue was complex and difficult to isolate. Initial investigations showed that the gasket material was compatible with the coolant it was sealing. So, what went wrong?
DISCOVERING THE ROOT CAUSE
After a detailed engineering review, the failure mechanism was uncovered. The issue wasn’t with coolant compatibility at all. It turned out that oil exposure during routine maintenance – specifically during oil changes – was contacting the gasket and degrading the material. The material, while suitable for coolant, wasn’t chemically resistant to oil.
This is a common oversight in sealing design; assuming that because a seal functions well with the primary fluid, it will also withstand incidental contact with others. In real-world applications, fluid contamination happens more often than many engineers expect, especially in shared environments like powertrain systems.
THE SOLUTION: DUAL COMPATIBILITY
Once the issue was identified, the team working on the automotive seal project partnered with one of their top elastomer suppliers to source a more chemically resilient material. The new gasket would need to resist both engine oil and coolant, and meet requirements for temperature extremes, pressure cycles, long-term durability, and manufacturability for high volumes.
The material selection phase involved lab testing and side-by-side comparisons of various compounds, evaluating their compatibility with both fluids as well as mechanical performance under simulated operating conditions. The ability to access advanced testing capabilities through supplier partnerships helped expedite this phase significantly.
REVERSE ENGINEERING
Interestingly, no formal drawing existed for the original gasket. The engineering team had to reverse engineer the component, creating a new design from the physical sample. Once the client approved the dimensional drawing, the tooling department got to work on a new mould for the replacement part.
Reverse engineering is often necessary for legacy or custom parts, especially when technical documentation is missing. It requires careful measurement and validation, but it also presents an opportunity to improve the design with updated materials and processes, especially when scaling up for high-volume production.
In this case, reverse engineering helped replicate the original geometry and allowed the team to fine-tune tolerances and incorporate subtle design enhancements based on field experience.
PROOF IN PERFORMANCE
Before scaling up to production, the team produced first article samples for real-world testing. These were evaluated for thermal stability, oil and coolant resistance, and dimensional integrity over time.
The outcome was promising. The samples not only passed, but exceeded, the performance thresholds set by the original design. With this validation in place, production moved forward.
According to the case study, the new gaskets have been in the field for over a year without a single warranty claim. This represents both major cost savings for the client and reflects improved reliability for their end-users. This example shows how a custom sealing solution – backed by good engineering and materials science – can make a tangible difference in product performance and brand reputation.
LOOKING AT THE LESSONS
This case provides several insights for anyone working with seals in demanding environments. First, cross-compatibility matters. Even limited of incidental fluid exposure can degrade materials over time, engineers must always consider the full spectrum of potential contact points. Second, reverse engineering can be a powerful tool. When drawings aren’t available, it’s still possible to recreate and improve upon a legacy part. Third, partnering with material experts can accelerate the development of solutions; the team’s ability to consult directly with advanced elastomer manufacturers made the process faster and more reliable. And last, testing before production saves costs later on. First article samples help to validate performance before OEMs commit to volume production.
GASKETS ARE SMALL, BUT CRITICAL
As automotive systems grow more complex, the materials used in even the smallest components need to perform in increasingly harsh and variable conditions. This case study serves as a valuable reminder that good sealing is not just about the shape of a part, but also about choosing the right material for real-world conditions.
It also highlights how forward-thinking engineering teams are going beyond troubleshooting to create proactive solutions that improve long-term system reliability. Strategic supplier collaboration, data-driven testing, and an openness to re-engineering legacy parts can dramatically shift outcomes for OEMs operating at scale.
