Industrial water jet systems rely on precision sealing to contain and control extreme force. Operating at up to 60,000 psi, a single compromised seal can stop production, damage equipment, and drive up maintenance costs.
A manufacturer of advanced water jet cutting equipment contacted Marco Rubber & Plastics after experiencing repeated seal failures in their piston assembly. Their standard seals could not handle the combination of high pressure, continuous reciprocating motion, and abrasive water flow. The company needed a custom-engineered solution that would perform reliably under extreme operating conditions and extend service life.
The Challenge
The application required a dynamic piston seal capable of maintaining performance at 60,000 psi during continuous reciprocating motion. Standard elastomer and unreinforced PTFE seals deformed, leaked, or extruded under load. Each failure led to costly downtime and repair work.
Key requirements included
- Resistance to extrusion and deformation
- Low friction during high-speed reciprocating motion
- Stable performance under temperature cycling
- Extended wear life with minimal maintenance
The sealing system had to maintain integrity through thousands of pressure cycles without losing shape or sealing force.
The Engineered Solution
Marco’s engineering team designed a custom hybrid sealing assembly specifically for high-pressure dynamic operation.
The system combined
- Filled PTFE for low friction and wear resistance
- A stainless-steel spring energizer to maintain consistent sealing force
- A backup ring system to block extrusion and stabilize the gland
Each component was optimized to distribute load evenly, manage pressure spikes, and maintain long-term dimensional stability. This custom design balanced flexibility and strength to perform reliably in extreme conditions.
At pressures this high, sealing performance depends on controlling extrusion and maintaining contact pressure. The spring-energized PTFE element provides flexibility and recovery through every pressure cycle. The backup rings absorb side loads and prevent material flow into extrusion gaps. Together, they maintain a secure seal that performs consistently even under thousands of cycles and thermal fluctuations.
The result is a dependable sealing system built to last through continuous, high-pressure operation.
Performance Verified Under Pressure
Testing confirmed full sealing integrity at 60,000 psi with no leakage, extrusion, or measurable wear after extended cycling.
The new design delivered measurable improvements:
- Reliable performance at 60,000 psi
- Long service life and reduced maintenance intervals
- Stable sealing behavior under reciprocating motion
- Consistent performance across temperature changes
Marco Rubber & Plastics paired advanced materials with precise engineering to create a durable sealing system that exceeded expectations. The result became the new standard for the customer’s production equipment.
The same engineering principles now support other industries where high-pressure sealing and motion intersect, including oilfield tools, hydraulic systems, and chemical injection pumps.
Contact Marco Rubber & Plastics to design a seal built specifically for your application.