Form-in-Place Gasket: Advanced Sealing Technology for Precision Applications
Form in Place gasketing is an excellent alternative for your applications that use die-cut gaskets, O-rings, or hand cut and applied extruded cord stock gaskets. With a Form in Place gasket you no longer need to waste time aligning a die-cut gasket, or chasing an O-ring into position, or having to cut, apply, and carry excess inventory of extruded cord stock. Our Form in Place gasket is dispensed and cured into position so that you can assemble and disassemble your enclosure as needed.
Our process of Form in Place gasketing (FIP) is done using a 3-axis or 4-axis robot that dispenses the silicone elastomer onto your parts gasket path which has been programmed into the robots by our experienced operators. We carry a variety of silicone elastomers in stock for your Conductive and Non-conductive gasket sealing needs. If the silicone elastomers we carry in stock do not meet your needs, we will work with you to find a suitable solution to help seal and protect your electronic application.
The Form in Place silicone elastomer can be dispensed on to injection molded plastics, machined plastic enclosures, machined metal enclosures, and even most rapid prototype enclosures.
What is a Form-in-Place Gasket?
Robotic dispensing of a form-in-place gasket on a precision metal housing
A form-in-place gaset is a sealing solution created by dispensing liquid material directly onto a component’s surface, where it cures in place to form a precise, custom seal. Unlike traditional pre-cut gaskets, FIP gaskets conform exactly to the component’s geometry, eliminating gaps and ensuring optimal sealing performance even with complex designs. The FIP process begins with a liquid elastomer (typically silicone or polyurethane) that is precisely dispensed by a robotic system along a programmed path. This material then cures at room temperature to create a resilient, durable gasket that provides reliable protection against environmental factors including moisture, dust, and electromagnetic interference (EMI).
Key Characteristics of Form-in-Place Gaskets:
- Precision application with tolerances as tight as ±0.1mm
- Seamless, continuous seal with no coupling points
- Ability to follow complex geometries and tight spaces
- Customizable compression force and resilience
- Available in both conductive and non-conductive formulations
- Cures at room temperature without additional processing
Robotically Dispensed In Place Gasket (RDIPG): Form In Place Gasket
Robotically Dispensed In Place Gasket of conductive or non-conductive bead diameter as specified In Vacuum Deposition/Metallization of 99.99% Aluminum onto plastic injection molded enclosures. RDIPG-Robotically dispensed in place gasket on to precision machined components supplied by the customer.
VTI form in place gasketing is a robotic system for dispensing elastomer onto a substrate to provide tightness of fit between plastic or metal parts that are screwed or snapped together for final assembly later in production.
VTI FIP gaskets can be conductive to augment shielding against EMI, RFI, and ESD; or they can be nonconductive to provide insulation from external contaminants and/or stress-relief.
VTI form in place technology features 3- and 4-axis CNC dispensing robots to assure repeatability and accuracy no matter how large or small your production run.
Advantages of Form-in-Place Gasket Technology
The advantages of form-in-place gasket technology make it particularly valuable for complex electronic enclosures, medical devices, automotive components, and other applications where reliability and precision are critical. While traditional gaskets may still be appropriate for certain applications, FIP gaskets offer compelling benefits for increasingly miniaturized and complex modern designs.
What are the kinds of available Form in Place (FIP) elastomers?
For conductive FIP gaskets, you can specify silicone elastomers composed of silver/nickel, silver/aluminum,
silver/copper, and nickel/graphite in either moisture- or thermal-cure formulations according to your needs.
What are the differences between Form in Place gasketing and Cure in Place gasketing?
Cure in place (CIP) gaskets are specified in cases where parts are assembled immediately on the line. In contrast to FIP gasketing, cure in place gasketing involves dispensing a silicone paste or adhesive onto the seam of one part of an enclosure and then attaching it to its opposite part while the silicone is still wet.
Once the silicone has cured, elastomeric cohesion provides sealing between the two. Thereby, CIP gaskets are not suitable for enclosures that are routinely taken apart for adjustment, maintenance, or battery replacement.
Find out more about our form in place gasketing capabilities
here.
Applications and Industries
Electronic Enclosures
FIP gaskets provide reliable environmental sealing and EMI shielding for electronic devices. The
precision application ensures protection against moisture, dust, and electromagnetic interference in
telecommunications equipment, control systems, and consumer electronics.
Automotive Components
From engine control units to lighting assemblies, FIP gaskets provide reliable sealing in harsh
automotive environments. Their ability to withstand temperature extremes, vibration, and exposure to
automotive fluids makes them ideal for critical vehicle systems.
Medical Devices
Medical equipment requires reliable sealing to maintain sterility and protect sensitive electronics.
FIP gaskets can be formulated with biocompatible materials.
Aerospace and Defense
Aerospace applications demand sealing solutions that can withstand extreme conditions. FIP gaskets
provide reliable protection against pressure differentials, temperature extremes, and vibration
while meeting stringent industry specifications.
Need a Custom FIP Gasket Solution?
Our engineering team specializes in developing form-in-place gasket solutions for
challenging applications across industries.
Form-in-Place Gasket Materials
Testing various FIP gasket materials for specific application requirements
The selection of the appropriate material is crucial to the performance of a form-in-place gasket. Different
applications require specific material properties to ensure optimal sealing and longevity. At Vactec, we work
with a wide range of materials to meet diverse application requirements.
Common FIP Gasket Material Types:
| Material Type | Key Properties | Temperature Range | Typical Applications |
|---|---|---|---|
| Silicone | Excellent temperature resistance, good compression set, UV stable | -60°C to +180°C | Outdoor electronics, lighting systems, solar equipment |
| Fluorosilicone | Excellent fuel and oil resistance, good temperature stability | -55°C to +175°C | Automotive under-hood, aerospace, fuel systems |
| Conductive Silicone | EMI shielding, environmental sealing, customizable conductivity | -55°C to +160°C | Telecommunications equipment, military electronics, medical devices |
Material Selection Considerations:
- Environmental Exposure: Temperature extremes, UV exposure, moisture levels
- Chemical Compatibility: Exposure to oils, fuels, cleaning agents
- Compression Requirements: Amount of force needed for effective sealing
- Electrical Properties: Conductivity needs for EMI shielding or electrical isolation
- Regulatory Compliance: Industry-specific certifications and standards
- Service Life Expectations: Durability requirements for the application
The Form-in-Place Gasket Dispensing Process
Advanced robotic system for precision FIP gasket dispensing
Key Steps in the FIP Gasket Production Process:
- Design Optimization: Engineering analysis to determine optimal gasket profile,
compression requirements, and material selection based on application needs. - Programming: Creating precise dispensing paths that follow the component geometry,
accounting for material flow characteristics and cure behavior. - Surface Preparation: Cleaning and treatment of component surfaces to ensure proper
adhesion of the gasket material. - Material Preparation: Conditioning gasket materials to optimal viscosity and
temperature for dispensing. - Robotic Dispensing: Computer-controlled application of the gasket material along
the programmed path with precise control of bead size and profile. - Curing: Allowing the material to cure at room temperature or accelerating the
process with controlled heat application. - Quality Verification: Inspection to ensure gasket dimensions, profile, and adhesion
meet specifications.
Precision Dispensing Technology
Vactec utilizes advanced robotic dispensing systems that deliver exceptional precision and repeatability. Our equipment can dispense gasket materials with tolerances as tight as ±0.1mm, allowing for application on surfaces as narrow as 0.4mm. This precision is critical for modern miniaturized components and complex geometries.
Close-up of precision dispensing nozzle applying FIP gasket material
Our robotic systems can accommodate both 2D and 3D component geometries, with multi-axis capability for complex parts. The dispensing parameters are precisely controlled to ensure consistent bead size, profile, and adhesion regardless of the complexity of the dispensing path.
Design Considerations for Form-in-Place Gaskets
Engineering design phase for optimal FIP gasket implementation
Successful implementation of form-in-place gaskets requires careful consideration during the design phase. Working with experienced FIP gasket engineers can help optimize your design for manufacturability, performance, and cost-effectiveness.
Critical Design Factors:
Surface Considerations
- Minimum Surface Width: Typically 0.4mm or wider for stable gasket formation
- Surface Flatness: Variations should be less than 0.4mm across the gasket
path - Surface Finish: Optimal adhesion requires appropriate surface preparation
- Corner Radii: Sharp corners may require adjusted dispensing parameters
Gasket Profile Design
- Compression Ratio: Typically 30-60% for polyurethane, 10-30% for silicone
- Cross-sectional Profile: Determined by sealing requirements
- Gasket Height: Typically 0.8-2.0mm with ±0.1mm tolerance
- Path Planning: Minimize starts/stops and optimize dispensing direction
Common Design Challenges and Solutions:
How do you handle vertical surfaces in 3D components?
during application and curing. Our dispensing parameters are adjusted to account for gravity
effects, ensuring consistent bead formation regardless of orientation.
What are the considerations for T-junctions and intersections?
buildup or gaps. We optimize the dispensing path to minimize starts and stops, often using
continuous path programming with adjusted flow rates at intersections to maintain consistent gasket
profile.
How do you ensure proper adhesion to different substrate materials?
specific surface preparation techniques and potentially different gasket materials. We conduct
adhesion testing with your specific materials to determine the optimal combination of surface
preparation, gasket material, and processing parameters.
Quality Assurance and Testing
Precision measurement of FIP gasket profile and dimensions
Quality assurance is critical for form-in-place gaskets, especially in applications where seal failure could have significant consequences. Vactec implements comprehensive testing protocols to ensure every gasket meets performance requirements.
Standard Testing Procedures:
- Dimensional Verification: Precise measurement of gasket height, width, and profile
- Adhesion Testing: Verification of proper bonding to substrate materials
Industry-Specific Testing:
| Industry | Specific Tests | Applicable Standards |
|---|---|---|
| Automotive | Temperature cycling, fluid immersion, vibration resistance | ASTM D395, SAE J2236 |
| Electronics | EMI shielding effectiveness, IP rating verification | MIL-DTL-83528, IEC 60529 |
| Medical | Biocompatibility, sterilization compatibility | ISO 10993, USP Class VI |
| Aerospace | Altitude testing, outgassing, flame resistance | AS5127, ASTM E595 |
Our quality assurance processes ensure that every form-in-place gasket we produce meets or exceeds the specified requirements. We maintain detailed documentation of all testing procedures and results, providing traceability and confidence in the performance of our gasket solutions.
Form-in-Place Gasket Success Stories
Automotive ECU Sealing Challenge
An automotive supplier needed a reliable sealing solution for a new generation
of engine control units exposed to extreme under-hood conditions. Traditional gaskets failed to
provide consistent protection against oil, fuel vapors, and temperature cycling.
Solution: Vactec developed a custom fluorosilicone FIP gasket
with excellent resistance to automotive fluids and temperature extremes from -40°C to +150°C.
The precision dispensing process accommodated the complex housing geometry with multiple
connector ports.
Result: 100% sealing reliability in field testing, elimination
of previous warranty claims related to fluid ingress, and simplified assembly process reducing
production time by 35%.
Medical Device Miniaturization
A medical device manufacturer needed to seal a miniaturized diagnostic device
with complex internal compartments. The design required multiple sealing paths on surfaces as
narrow as 0.5mm while maintaining biocompatibility.
Solution: Vactec implemented a USP Class VI silicone FIP
gasket with micro-dispensing technology, creating precise seals on the narrow surfaces while
maintaining clean room production standards.
Result: Successful sealing of the miniaturized device,
enabling a 40% size reduction from previous generation while maintaining IP67 protection and
passing all biocompatibility testing.
EMI Shielding for 5G Equipment
A telecommunications manufacturer needed both environmental sealing and EMI
shielding for outdoor 5G equipment. The complex housing design included multiple compartments
with different shielding requirements.
Solution: Vactec developed a silver-filled silicone FIP gasket
with customized conductivity for different housing sections. The material provided both
excellent environmental sealing and >80dB shielding effectiveness across the required
frequency range.
Result: The equipment passed all environmental and EMI testing
requirements while reducing assembly time by 50% compared to the previous mechanical shield
design.
Partner with Vactec for Your Form-in-Place Gasket Needs
Our engineering team collaborating on custom FIP gasket solutions
With decades of experience in precision dispensing technology, Vactec is your ideal partner for form-in-place gasket solutions. Our engineering team works closely with you from initial design through production, ensuring optimal performance and reliability for your specific application.
Why Choose Vactec for Your FIP Gasket Needs:
- Engineering Expertise: Our team specializes in gasket design optimization for
complex applications - Material Selection: Access to a wide range of materials to meet specific
application requirements - Advanced Equipment: State-of-the-art robotic dispensing systems for unmatched
precision - Quality Assurance: Comprehensive testing protocols ensure reliable performance
- Production Flexibility: Capabilities for both prototype development and high-volume
production - Industry Experience: Proven success across automotive, electronics, medical, and
aerospace applications
Ready to Discuss Your Form-in-Place Gasket Requirements?
Contact our engineering team today to explore how our form-in-place gasket
solutions can enhance your product’s performance and reliability.
