Aerospace manufacturing demands sealing precision. Every o-ring must perform flawlessly under pressure, temperature, and chemical exposure. Even a minor fit or compression issue can cause leaks, contamination, and costly production delays.
After repeated seal failures in a critical pump assembly, a leading aerospace manufacturer reached out to Marco for help with identifying the cause and restoring reliability.
The Challenge
The manufacturer was facing recurring o-ring failures in the compression chambers of a resin pump system. Oversized silicone o-rings created a loose groove fit that allowed the seals to bunch and deform under pressure.
Each failure resulted in chemical leaks, process interruptions, and additional maintenance time. This was not limited to one batch. Rather, it was systemic, caused by incorrect sizing relative to the groove dimensions.
The customer needed a precise fit that would maintain compression without distortion and hold up through repeated cycles.
Marco’s Engineering Approach
Our engineering team began by inspecting the failed o-rings and measuring the pump’s groove dimensions. The review confirmed the seals were too large for the gland, causing them to twist and tear during compression. The updated seals achieved full compression without distortion and maintained consistent contact throughout the cycles.
Using the measurements, Marco identified the correct size and supplied custom o-rings precisely matched to the groove geometry. The updated seals achieved full compression without distortion and maintained consistent contact throughout the cycles.
Proven Results from Marco
The new o-rings fit precisely within the groove, creating full compression without distortion or surface damage. During testing, the seals maintained consistent pressure retention and showed no leaks or deformation after repeated cycling.
Once implemented in production, the results were immediate:
- Continuous pump operation with no seal failures
- Leaks and chemical spills fully eliminated
- Significantly reduced maintenance frequency
- Extended seal-replacement intervals
- Improved uptime and system reliability
By addressing the o-ring-sizing and groove-fit problem at the source, Marco helped the customer achieve a stable, repeatable seal that improved reliability, safety, and throughput across their manufacturing process.
Precision That Delivers
In aerospace applications, seal reliability starts with proper sizing and groove design. Even small dimensional mismatches can compromise compression and lead to failures.
Marco Rubber & Plastics provides the expert engineering support you need. Every seal performs as intended, preventing leaks, extending component life, and maintaining the precision your systems demand.
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Contact Marco Rubber & Plastics for expert guidance on o-ring sizing, groove design, and custom aerospace sealing solutions.