Common Aerospace Applications for Rubber Seals & Spacers

Rubber is a very effective sealing solution for various industries, especially the aerospace industry. Rubber is frequently chosen for sealing due to its numerous advantageous properties. It is a strong material that maintains flexibility and optimal performance even in extremely high and low temperatures, which is essential to the aerospace industry.

Rubber has additional benefits, such as low chemical reactivity; low outgassing; and resistance to acids, bases, water, oil, and fungus. Additionally, rubber is easy to mold into various shapes and provides excellent insulation for electrical components. Throughout the aerospace industry, rubber seals are found in many applications, from engines and windows to the cockpit and cabin.

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Top 5 Uses of Rubber Seals in the Aerospace Industry

Rubber seals and spacers are used widely throughout the aerospace industry in applications relating to both space exploration and aviation. Rubber extrusions, such as O-rings, are used in connectors and bleed air valves. Rubber is also used to produce T-seals; hatch seals and covers; tubing; as well as protective boots, bellows, and many other components. Let’s take a look at the top 5 applications for rubber seals in the aerospace industry.

Thermal Insulation and Protection

The aerospace industry requires equipment to function correctly at high altitudes, where temperature decreases significantly. In these challenging environments, rubber seals are a critical solution as they offer reliable protection and thermal insulation. During atmospheric reentry, high levels of friction occur which creates extremely high temperatures on the surface of the vehicle. Rubber seals can withstand these extreme temperatures, protecting inside passengers.

In the aviation industry, aircraft systems rely on pneumatics and hydraulics to operate components such as landing gear and wing flaps. These systems require rubber gaskets to keep out dirt and air and ensure aircraft components function correctly. Rubber is an optimal material for applications that require a compressible gasket.

Interior Components

Normal aircraft operation creates a significant level of noise and vibrations that could disturb passengers. When used on internal components, rubber seals provide a more comfortable and safe environment by significantly reducing these sounds and vibration levels. Rubber seals can be used on many interior components, from hatches to gaskets for LED lighting systems.


Rubber seals are found in HVAC seals, gaskets, and vent ducts throughout aircraft to provide ventilation. In commercial and military aviation, rubber seals are used to keep air from escaping the aircraft through gaps around windows and doors. This ensures that cabin pressure and oxygen levels remain stable and at appropriate levels.

Engine Components

Rubber seals’ high heat and corrosion resistance make them optimally suited for several engine-related applications. They are frequently found in several engine components, such as gaskets, to support the engine when it experiences high temperatures during lift-off. They also provide shock absorption and improve aircraft safety while reducing maintenance costs.

Additionally, aerospace turbine engine shaft seals function by sealing the main shaft bearing compartment and oil sump to ensure correct operation. Seals around aircraft firewalls are an essential aspect of the engine compartment. To protect passengers from an engine fire, a sturdy fireproof barrier is needed between the engine and the cockpit, and rubber seals are an important component of this barrier.

General Mission Critical Equipment

Throughout mission-critical systems, rubber seals’ fire-retardant and grounding capabilities make it an excellent choice to protect vital electronic components. Rubber seals are used to keep out environmental contaminants and are also used throughout motion control, communication, and navigation systems. Rubber seals can be used to seal instrument panels and other electrical systems in the cockpit. This helps protect printed circuit boards from the risks associated with extreme altitude.

Rubber Seals & Spaces from Thomas A. Caserta, Inc.

Lightweight but highly durable, rubber is a frequently chosen material for aerospace applications due to its reliable performance in challenging environments. Thomas A. Caserta, Inc. understands the unique needs of the aerospace industry and has been manufacturing high-quality rubber products for over 70 years. We are highly experienced at producing rubber seals and spacers with the level of precision that the aerospace industry requires. All of our products can be manufactured to precise specifications and are carefully crafted in the USA. To learn more about our products and services, contact us today.

Rubber Products in the Aerospace Industry

The aerospace and aviation industry is one of the fastest growing industries on a global scale, affecting millions of people on a daily basis.

Reliable aircraft demands top tier components. These parts must have properties of high performance and endurance, since they will be exposed to a range of extreme weather conditions, such as excessively hot or cold temperatures, and different types of oils and gases. It is crucial that jets, commercial planes, and other aircraft can protect both passengers and cargo from the elements.

Many aerospace and aviation components are now being sourced from rubber. Rubber products are becoming more popular due to their durability under extreme environmental conditions and cost-effectiveness.

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Rubber Designed for Flight

Rubber products are an excellent option for flight applications. Synthetic rubbers from various sources can withstand highly aggressive aerospace fluids, including:

  • Engine lubrication oils
  • Jet fuels
  • Hydraulic fluids
  • Oxidizers
  • Rocket propellants

Some of the common materials that engineers utilize for aerospace and aviation applications include:

  • Neoprene. This is a good general purpose elastomer that has many desirable characteristics. It has high resilience with low compression set and boasts moderate oil, ozone, and water resistance. It successfully operates within a temperature range of -65°F to 260°F. However, neoprene is not recommended for certain applications like phosphate esters, ketones, and brake fluids.
  • EPDM. Also known as Ethylene Propylene Diene Monomer, EPDM contains excellent weatherability properties and low gas permeability. It works within a temperature range of -60°F to 280°F. While it is highly resistant to ozone, water, brake fluids, and other substances, it has a low resistance threshold for petroleum oils and diester lubricants.
  • Silicone. Able to effectively operate in temperatures from -150° to 500°F, silicone boasts the greatest total temperature range of currently used elastomers. While it also has excellent resistance to a number of environmental conditions and outside substances, such as dry heat, brake fluids, and high aniline point oils, it is not an optimal solution for certain applications due to poor tensile strength and tear.

rubber uses in aerospace

Rubber materials have an array of qualities that make them the perfect choice for aerospace and aviation applications. Some characteristics that stand out include:

  • A high endurance threshold under extreme stresses
  • Endurance under extreme temperatures
  • No need for lubrication between parts
  • Very little maintenance required, if any
  • Sound and shock absorption
  • Long life spans

Applications That Demand Rubber Products

Rubber products have become popular across a broad spectrum of industries. In the aerospace and aviation industry, they have delivered superior performance in applications, such as:

  • Thermal insulation
  • Window and door seals
  • HVAC seals and gaskets
  • LED lighting gaskets
  • Vent ducts
  • Vibration dampening
  • Instrument panel seals and engine gaskets
  • O-rings utilized in connectors, valves, and other applications
  • Hydraulic actuators
  • Bleed air valves and fittings
  • Firewall seals
  • T-seals
  • Bumpers
  • Hatch seals and covers
  • Rubber extrusions
  • Extruded tubing and seals
  • Protective boots and bellows

At Thomas A. Caserta, our rubber products are highly customizable according to customer needs and preferences. Our engineers and technical specialists take great pride in designing and supplying safe, robust, and specialized rubber product solutions for a variety of needs.

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Contact the Aerospace Rubber Manufacturing Experts

The team at Thomas A. Caserta works hard to ensure that each part for our customers meets or exceeds all the relevant industry specifications and standards. All our custom rubber aircraft components are manufactured in-house, and our stringent quality control protocols and attention to detail guarantee that each client receives a premium product for their particular need.

If you would like to learn more about our manufacturing capabilities or are interested in partnering with us for your aerospace/aviation product needs, reach out to us today.