What are Gasket Materials?

What is a gasket material?

Gasket material is a key element of gasket manufacturing, which determines the type of function of the gasket and its service conditions. The purpose of gaskets is to prevent leaks, seal connections and keep contaminants out of critical processes.

Pressure and temperature are the determining factors in the choice of gasket material and its compatibility with the application. Proper selection of materials ensures that processes operate properly and efficiently without the need for maintenance or repair.

Gasket material and its function

There are several options when selecting a gasket material or building a custom gasket. Some popular gasket material categories include:

Solid material

Solid materials are often an alternative to sponge materials. They have the advantage of making the gasket more durable and last longer. Solid gaskets last twice as long as sponge materials. Additionally, solid materials can withstand higher compressive forces than sponges and are therefore recommended for applications that need to handle high compressive forces.

Solid gasket

Forming processes such as water jet cutting, die cutting and CNC cutting can be used to form solid materials into gaskets. These solid materials have the ability to be molded in three dimensions.

Some solid materials used to form gaskets include:


Gaskets designed from solid silicone are primarily used in outdoor applications. They are suitable where the physical characteristics of the environment are not so important. However, resistance to extreme temperatures is still required. Examples include applications prone to degradation from sunlight exposure.

Fluorosilicone rubber

Gaskets made from fluorosilicone can be used in the same conditions as silicone, although they have the added advantage of chemical resistance. Fluorosilicone's resistance to chemicals such as fuels and oils and resistance to extreme temperatures make fluorosilicone resins best suited for fuel delivery applications in the automotive and aerospace industries. Fluorosilicone costs more than silicone because of the added advantages.

Fluorosilicone rubber gasket

Nitrile rubber

Gaskets made of nitrile are suitable for extreme environments and high wear industrial applications. Nitrile is a tough and durable material that is also resistant to chemicals such as oils and fuels. Other versions of nitrile are available for food and agricultural applications.


Gaskets made of neoprene are more cost-effective than fluorosilicone and silicone. Neoprene is best suited for applications that require resistance to fluids such as oil and water. Neoprene is also highly resilient and elastic, which allows it to withstand elongation and tearing better than silicone. It is also fatigue and abrasion resistant.

Ethylene Propylene Diene Monomer (EPDM)

Gaskets made of peroxide-cured EPDM rubber widely use rubber with good weather resistance, water resistance, ozone resistance, and UV resistance. As peroxide cured EPDM cures, thermal stability allows peroxide cured EPDM to resist steam and extreme temperatures. Depending on the application, peroxide cured EPDM is less costly than silicone. However, peroxide cured EPDM is not best suited for oily applications.

EPDM rubber gasket


Butyl rubber is a synthetic rubber that is resistant to chemicals and oils. It repels moisture and does not allow gas to escape. Butyl rubber is commonly used in medical and aerospace applications.


Fluoroelastomer is the best choice for solid materials because it offers synergistic benefits for all solid materials. Some benefits include resistance to chemicals and extreme temperatures. However, it is more expensive than all other solid materials. It is mainly used in the aerospace industry where all these characteristics are required.

Fluorocarbon gasket

Fluorocarbon gaskets have a flat cross section and are reusable for non-critical applications. They are widely used in applications requiring frequent reassembly. Fluorocarbon gaskets are an alternative to copper gaskets for sealing flat flanges. They are not used in high temperature applications because they lose strength with increasing temperature.

Sponge material

Pads made of sponge material are mainly used at low compression forces. Sponge material should be selected in the following cases:

Case components are prone to bending or warping

The case may crack when the compression stops or use a plastic case. Thus, the sponge material makes these shells less susceptible to compressive forces. They are sometimes preferred over solid materials due to their UL flammability rating. Easier to find than silicone sponge material with a UL94V-0 flammability rating, for example