Published
by Rogers Corporation
Enclosure Institute, Elastomeric Material Solutions
Welcome back to the Marian and Rogers Enclosure Institute™, your trusted resource for mastering enclosure design and sealing solutions.
The value of having a reliable enclosure seal is directly tied to the value of what’s being protected inside the enclosure. That value might be intrinsic, such as the high cost of replacing or repairing sensitive electronics, or extrinsic, such as the downstream cost of failures or downtime.
Consider a reservoir monitoring system where sensors gather and transmit water level data. These electronics are housed in outdoor enclosures that face harsh conditions. If a storm or hurricane forces water past the seal, the damage could be significant — not only due to the cost of replacement and repairs, but also because the loss of data might create dangerous conditions before the problem is even detected.
The good news is that gasket reliability can be predicted and validated. Through targeted reliability testing, engineers can evaluate how a gasket will perform under specific conditions over time, ensuring it maintains a tight seal and does not fail prematurely.
These tests simulate real-world stressors, such as temperature swings, mechanical loads, pressure cycling, and chemical exposure, to verify a gasket’s long-term durability and performance.
In this blog, we’ll explore why reliability testing matters, key test methods, and how engineers can use testing data to design seals that last.
Reliability testing is essential because a seal failure can have far-reaching consequences. It helps engineers:
Test Method: ASTM D3574 or ASTM D1056.
What it Measures
The ability of a gasket to return to its original thickness after being compressed for a period of time. This directly relates to how well the material maintains long-term sealing force.
How it Works
Materials are compressed to 50% of their original thickness and held compressed for a defined period under specific environmental conditions (e.g., elevated temperature or humidity).
Customers can select conditions that replicate their application, while accelerated heat aging can simulate long-term field performance.
At the end of the compression and hold period, the load is released, and the material is allowed to expand. A reliable gasket material will typically recover to within 5% of its original thickness — though this depends on the severity of the testing conditions.
Test Method: ASTM D6147 or ISO 3384.
What it Measures
How much sealing force a gasket loses over time while compressed, which is crucial to maintaining a tight seal.
How it Works
A material is compressed to a specified deflection, and the pushback force it exerts is measured over time. This testing evaluates how the material relaxes under compression and can include temperature and humidity variations to simulate real-world operating conditions. As the material relaxes, its ability to maintain pressure on the sealing surfaces diminishes, which can lead to seal failure.
What it Measures
The gasket’s ability to maintain performance when exposed to repeated heating and cooling cycles to simulate real world conditions.
How it Works
Materials are exposed to controlled temperature and humidity cycles that mimic the operating environment of the enclosure. Testing can be conducted while the gasket is compressed or uncompressed. After cycling, sealing properties like compression set are evaluated to determine whether the gasket can maintain its sealing ability after thermal expansion and contraction.
What it Measures
The gasket’s durability when exposed to chemicals, fluids, or gases relevant to the application.
How it Works
Materials are immersed or otherwise exposed to chemicals relevant to the application, and their physical properties are measured over time. Sealing materials aren’t typically used in tensile modes, but tensile strength is often used as an early indicator of degradation because it is usually the first property to weaken. A significant reduction in tensile strength signals that the material’s performance may be compromised.
What it Measures
The ability of a fully assembled enclosure, not just the gasket material, to resist dust and water ingress.
How it Works
This testing subjects an actual enclosure to conditions involving dust and/or water exposure. It is an application-level test, not a material test, because it evaluates how the gasket, enclosure design, and assembly work together to create a reliable seal.
Dust:
Left: IP 5X and 6X testing machine. Right: Inside the machine after testing
Empty fixtures after testing showing no ingress of powder
Water:
Left: One meter water tank for immersion. Right: Vessels after testing with membranes on top
Vessels opened, showing no ingress of water
Image property of Marian, Inc.
Water and dust ingress remain among the most common causes of enclosure failures. Even the best gasket materials can fail if not properly compressed, sized, or matched to the enclosure design. IP testing helps engineers:
Reliability testing ensures that a gasket performs not just on day one but throughout its entire service life. By combining compression set, stress relaxation, thermal cycling, IP ingress testing, and chemical resistance, engineers can build confidence that their seals will withstand real-world demands.
Sealing challenges can make or break an enclosure’s performance. Whether you're designing for environmental protection, long-term reliability, or compliance with industry standards, selecting the right materials and understanding effective sealing strategies are critical. That’s why Marian Inc. and Rogers Corporation have partnered to bring you the Enclosure Institute—a free learning platform designed to help engineers navigate the complexities of enclosure sealing.
Gain exclusive access to:
The Enclosure Institute is designed for engineers at all levels, whether you're new to enclosure sealing or looking to refine your expertise.
Enroll today to take the next step in mastering enclosure design.
If you have a specific enclosure challenge and need expert guidance, Marian’s team is ready to help. Contact Marian directly for tailored recommendations and support.
Not ready to enroll yet? Explore more blogs on enclosure design best practices:
With nearly 200 years of material expertise, 70 years of fabrication development, decades of partnership, and thousands of applications designed together, Marian and Rogers bring unmatched knowledge to enclosure sealing. By combining Rogers’ high-performance materials with Marian’s precision converting capabilities, we deliver custom-engineered solutions that enhance durability, reliability, and performance.
Whether you need expert guidance, high-quality materials, or precision-fabricated components, our partnership ensures your enclosures meet the highest industry standards while optimizing efficiency and cost-effectiveness.
Published on Aug 27, 2025
