Medical device performance depends on consistent and reliable sealing. A small variation in o-ring size or tolerance can cause leaks, assembly issues, or premature wear.
After o-rings in a clamp system began failing early, a medical device manufacturer reached out to Marco Rubber & Plastics. The parts met spec but created too much compression during installation. This made the assembly difficult and caused surface abrasions that reduced seal life.
The Challenge
The clamp system’s o-rings were difficult to install and were wearing out too quickly. While the seals were within tolerance, the subtle size differences led to excessive compression force during the assembly process.
The excess compression caused the o-rings to drag and abrade against the hardware, which shortened their service life and slowed production. The manufacturer needed a way to maintain a secure, leak-free seal while reducing wear and improving assembly.
Marco’s Solution
Marco’s engineering team reviewed the worn o-rings and measured the groove dimensions to pinpoint what was causing the seals to wear out early. Using Poisson’s ratio (which indicates how much thinner a material becomes along one dimension when stretched along another), the team assessed how the o-ring’s cross section changed when stretched during installation.
The team found that the diameter of the o-ring was shrinking slightly under tension, reducing its ability to fill the groove evenly and increasing compression force once installed. Marco recommended a slightly smaller o-ring size to offset this effect and achieve proper compression. The new seals installed smoothly, maintained a tight fit, and showed no surface wear during testing.
Proven Results
Testing confirmed that the updated o-rings achieved a precise groove fit with balanced compression and no surface abrasion. Installation became faster and more consistent. The drag and deformation that had caused the earlier failures were eliminated.
The improved sizing extended seal life and reduced replacement frequency. To standardize performance and streamline assembly, the medical manufacturer adopted the updated design across all clamp assemblies.
Reliable Sealing for Precision Medical Systems
In medical and pharmaceutical equipment, even small dimensional changes can affect sealing performance and product integrity. For precise, repeatable assembly, Marco Rubber & Plastics provides engineering support to optimize o-ring sizing, groove design, and material selection.
Through detailed analysis and testing, Marco helps manufacturers improve reliability, extend seal life, and maintain consistent performance in critical systems.
Contact Marco Rubber & Plastics for expert support on o-ring sizing, groove design, and more.