Published
by Rogers Corporation
Elastomeric Material Solutions, Enclosure Institute
Welcome back to The Enclosure Institute™, where we uncover the science and strategy behind reliable, long-lasting enclosure design.
In this blog, we look ahead to the future and explore how emerging technologies and evolving markets are reshaping what it takes to seal, protect, and perform.
A decade ago, few engineers imagined that electric vehicles be comparable to gasoline models in new car launches, or that data centers would be treated like critical infrastructure. Medical devices were mostly stationary, and energy storage systems were still experimental.
Today, markets are expanding rapidly, reshaping how we think about enclosures and sealing. As designs grow smaller, lighter, and smarter, the same materials that once defined "high performance" are being pushed to new limits.
At the Enclosure Institute™, we study what is coming next and identify the trends already influencing the next generation of sealing solutions.
Image property of Rogers Corporation. Image generated by Gemini.
The drive for lightweight enclosures is accelerating.
In markets such as automotive and EV, thinner metals and advanced thermoplastics reduce mass to extend range and improve efficiency. In aerospace and mass transit, every gram saved helps conserve fuel. Even stationary systems like medical devices and BESS enclosures benefit from thinner designs that simplify installation and lower costs.
However, thinner walls often mean lower closure forces, which makes softer, more conformable sealing materials essential for maintaining compression and long-term reliability. These new materials are being developed in Rogers laboratories today.
Thinner, less rigid enclosures also heighten the need for controlled venting.
Venting helps regulate internal pressure, preventing fatigue or premature failure in sensitive electronics.
The data center environment illustrates this well. Servers experience large temperature swings, making pressure equalization and moisture control critical for uptime and reliability.
In BESS units and EV battery packs, venting systems allow gases to escape safely while keeping contaminants out.
Medical devices also use micro-venting solutions to manage internal pressure without compromising sterility or performance.
Image property of Rogers Corporation. Image generated by Gemini.
Safety standards continue to evolve, especially in markets where even one incident can attract global attention.
EV and BESS applications are leading the shift toward stricter UL 94 V-0 requirements and updated HBF classifications. Medical electronics and data centers face similar pressure to improve compliance and minimize fire risk.
To meet these demands, Rogers is introducing new materials such as softer UL 94 V-0 rated PORON® foams and next-generation HBF materials that balance flame resistance with the flexibility needed for thinner, lighter enclosures.
New PORON® 40V0 material. Image property of Rogers Corporation.
Connected devices are everywhere. From smart home systems to vehicle monitoring and medical diagnostics, sensors are multiplying across every market.
Each requires an enclosure that protects delicate electronics from the environment while maintaining responsiveness and signal accuracy. These enclosures are smaller, thinner, and more exposed than ever, demanding high-precision seals that combine flexibility with protection.
Image property of Rogers Corporation. Image generated by Gemini.
Climate extremes are creating new expectations for enclosure performance.
Outdoor systems such as BESS, EV charging, and telecom equipment must meet higher NEMA and IP ratings to withstand real-world environments. Stress relaxation testing and other predictive methods are now being used to ensure long-term seal integrity under shifting conditions of temperature, moisture, and pressure.
Image property of Rogers Corporation. Image generated by Gemini.
Devices continue to do more in smaller spaces.
In data centers, increasing computer density generates more heat.
In EVs and BESS systems, designers must manage both external climate exposure and internal energy output.
Even handheld medical devices face rising thermal demands as electronics grow more powerful.
Future sealing materials will need to combine strong sealing performance with enhanced temperature resistance, supporting devices that not only work harder but also last longer.
From data centers to EVs, from medical devices to BESS, tomorrow’s applications will challenge enclosure design in every way.
Thinner structures, higher safety standards, more sensors, harsher environments, and rising heat loads are all shaping the materials of the future.
At the Enclosure Institute, we are not only tracking these trends but preparing for them.
The materials being developed today are designed to solve the challenges engineers will face tomorrow.
Stay tuned for future Enclosure Institute modules, where we will explore these markets in greater depth and highlight the technologies defining the next generation of sealing.
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 Oct 28, 2025
