High-Volume EPDM Gasket Program for HVAC OEM
Challenge · Solution · Result
HVAC component manufacturer needed a consistent EPDM flat gasket with ±0.1mm thickness tolerance, stable Shore A 55±3 hardness, and 100% sealing integrity across 500,000 units/month production volume.
Developed multi-cavity compression mold with automated flash trimming line. Implemented 100% optical dimensional inspection with automated reject sorter. All batches tested for Shore A and compression set.
Process CPK 1.89 on thickness. Shore A 55 ± 2 across entire production run. Zero reported field leak failures across 18-month supply agreement.
Engineering Insights
DFM Analysis & Process Optimization
DFM Analysis: Flash trim path engineered to eliminate micro-burrs that were causing installer finger injuries. Mold cavity surface Ra <0.4μm for clean flash separation.
Our engineers work from your CAD drawings before any tooling begins — identifying potential failure modes, proposing material alternatives, and validating gate/cooling layouts digitally. This eliminates costly mold revision cycles.
Empirical Test Data
Physical test results from production samples — available with every shipment on request.
| Property | Specification | Result |
|---|---|---|
| Thickness Tolerance | ±0.1mm | CPK 1.89 |
| Shore A Hardness | 55 ± 3 | 55 ± 2 |
| Compression Set (70h/70°C) | ≤ 25% | 18% |
| Tensile Strength | ≥ 10 MPa | 12.3 MPa |
Get an Engineering Quote Within 24 Hours
Share your drawings, quantity and material requirements. Our team performs a complimentary DFM review before quoting.
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