#* * Customized Sealing O-ring Technical Guide**

## **1. The core value of customized O-rings**

Customized O-ring is a sealing solution designed for special working conditions, breaking through the limitations of standard parts and providing optimal sealing performance in extreme temperature, pressure, medium or size environments.

###* * Typical customized scenarios**

-* * Non standard size * *: Irregular cross-section/oversized/undersized specifications (such as Ø 0.5mm O-ring for micro medical equipment)

-Extreme working conditions: ultra-high pressure (>300MPa), cryogenic (-196 ℃ liquid nitrogen), strong corrosion (98% concentrated sulfuric acid)

-* * Composite function * *: Special performance requirements for conductivity/flame retardancy/anti-static, etc

-Industry Compliance: FDA Medical Grade, Aerospace AS9100 and other certification requirements

## **2. Customize key parameter matrix**

|Parameter dimension | Optional range/options | Professional technical advice|

|----------------|-----------------------------------------------------------------------------|-----------------------------------------------------------------------------|

|* * Dimensional accuracy * * | • ID 0.3mm~5000mm<br>• Section diameter 0.3~30mm<br>• Tolerance ± 0.01mm (precision grade) | It is recommended to choose ISO 3601 Grade 1 tolerance (± 0.04mm) for the medical/semiconductor industry|

|* * Material System * * | • Conventional Rubber: NBR/FKM/EPDM, etc.<br>• Special Materials: Perfluoroether Rubber (FFKM)/Hydrogenated Nitrile (HNBR)<br>• Composite Material: PTFE Coating/Metal Reinforcement | Kalrez is preferred for strong acid environments ®  6375(FFKM)； <br>Recommended polyurethane AU material for ultra-low temperature (maintaining elasticity at -80 ℃)|

|* * Special performance * * | • Conductivity (volume resistance<10 Ω· cm)<br>• Flame retardant rating (UL94 V0)<br>• Low friction (μ<0.1) | Explosion proof scenarios must meet both conductivity and flame retardant requirements; <br>Suggest adding MoS ₂ self-lubricating agent for dynamic sealing|

|* * Structural improvement * * | • X-shaped/square shaped and other irregular cross-sections<br>• Built in spring compensation structure<br>• Multi lip sealing design | It is recommended to use a stepped cross-section for reciprocating seals; <br>It is recommended to add a nylon anti extrusion ring to the large-diameter O-ring|

## **3. Industry customized case library**

###Case 1: Semiconductor dry etching equipment**

-* * Challenge * *: Need to withstand plasma corrosion+150 ℃ high temperature

-* * Plan * *: Using FFKM material+PTFE surface coating

-* * Parameter * *: Shore A 75 °± 3, deflation rate<0.01%

###Case 2: Deep sea drilling blowout preventer**

-Challenge: 350MPa water pressure+H ₂ S corrosion

-* * Scheme * *: NBR core+316L stainless steel ring reinforcement

-* * Lifespan * *: 8 times longer than standard parts, up to 50000 cycles

###Case 3: mRNA vaccine production**

-* * Requirement * *: FDA Class VI certification+steam sterilization capability

-* * Material * *: Platinum sulfide silicone (no precipitates)

-Cleanliness: Particle release<5/ft ³ (0.5 μ m)

## **4. Customized development process**

1. * * Requirement analysis * *: Fill in the working condition survey form (medium/temperature/pressure/motion mode)

2. * * Material selection * *: The laboratory provides three or more material options

3. * * Prototype testing * *:

-Basic Test: Compression Permanent Deformation (GB/T 7759)

-Working condition simulation: salt spray test/swelling test, etc

4. * * Small batch trial production * *: Provide 50-100 samples for verification

5. * * Mass production optimization * *: SPC control critical dimension CPK ≥ 1.33

## **5. Cost optimization strategy**

-Mold solution:<50000 pieces can choose aluminum molds (cost reduced by 60%)

-* * Alternative Material * *: Use Aflas ® Replace Kalrez ® Can reduce costs by 40% (limited to below 150 ℃)

-Process selection: Compression molding is suitable for complex structures, while extrusion vulcanization is suitable for large quantities

## **6. Quality Control System**

-* * Testing equipment * *:

-3D optical measuring instrument (accuracy 0.001mm)

-FTIR Infrared Spectroscopy Material Analysis

-Helium mass spectrometry leak detection (sensitivity 10 ⁻⁹ Pa · m ³/s)

-Certification Standards:

-Automobile: ISO 9001+IATF 16949

-Medical: ISO 13485+USP Class VI

## **7. Technological development trends**

-Intelligent O-ring: Embedded with RFID chip to record usage parameters

-* * Self healing material * *: Microencapsulated healing agent automatically repairs cracks

-* * 3D Printing * *: Used for rapid prototyping of small batch irregular O-rings

## **8. Suggestions for choosing customized services**

Prioritize selecting suppliers with the following qualifications:

-Having a material formula laboratory

-Provide a simulation test report for working conditions

-Having supply experience in the military/medical industry

-Can provide a comprehensive solution for sealing systems

>* * Note * *: The customization cycle is usually 4-8 weeks, and urgent needs can choose the existing mold repair plan (delivered within 2 weeks). Suggest leaving a 10% margin to cope with fluctuations in operating conditions.