FIP Liquid Gasketing: The Future of Industrial Sealing

What Is FIP (Form-in-Place)?

Formed-in-place gaskets are a versatile, cost-effective type of gasket used in many fields, including robotics, EVs, and UAVs. The term “form-in-place” or FIP refers to how the gasket is installed. Unlike other traditional pre-formed gaskets produced by punching sheet materials and fitting them into assemblies, FIP gaskets are dispensed as a liquid material, like silicone, onto a surface and cured using light, heat, or moisture.

Because the gasket material begins in liquid form, it’s easy to achieve a precision fit. The liquid material only fills the space it needs to, conforming snugly to a part’s form, regardless of any imperfections that may be present in the housing. The finished product is not only durable but also achieves a tight, reliable seal.

FIP gaskets are dispensed by CNC equipment for optimal precision, making it possible to form a gasket on complex or small surfaces, even those less than one millimeter wide. FIP gaskets and dispensing equipment from H&S Manufacturing can reliably seal materials with precision and repeatability. Learn more about the benefits of form-in-place gaskets, their common applications, and future uses of these innovative materials.

Benefits of Form-in-Place Gaskets

Since liquid-form FIP gasket materials are cured directly within a product’s housing, these gaskets deliver many unique benefits, such as:

Precision

Dispensing liquid-form gaskets allows them to fill extremely precise or complex shapes, creating tight seals that other types of gaskets cannot achieve.

Durability

FIP gaskets are made using materials that can withstand extreme temperatures, corrosion, repeated force, and UV exposure. They offer reliable durability in many engineering applications.

Flexibility

FIP gaskets can fit virtually any size configuration, large or small.

Zero Waste

Unlike other production methods, form-in-place gaskets don’t leave excess material behind. There is no cutting or binding—only the exact amount of material needed to fill the space.

Reduced Assembly Steps

Methods like die cutting and extrusion require someone to apply the gasket to its housing. However, FIP gaskets are dispensed and cured directly in their housing, minimizing assembly steps and production costs.

Common Applications of FIP

Due to their unique manufacturing and performance advantages, FIP gaskets are used throughout an extensive range of industries. They are particularly effective in protecting against EMI, water, dust, and other damaging environmental conditions. At H&S Manufacturing, we develop custom FIP gaskets for industries such as:

Aerospace

FIP gaskets are found in aircraft seats, ground support equipment, drones, and flight instruments.

Automotive

Automotive doors, windows, external engine parts, and air and oil filters all use form-in-place gaskets.

Electric Vehicles

FIP gaskets are a vital element of EV battery systems, where they separate and protect battery panel sections.

Chemical Processing

Processing systems and equipment feature FIP gaskets for precise, reliable sealing.

Electronics

Semiconductors, electronic enclosures, and communication systems all require reliable gaskets.

Energy

Generators, transformers, and alternative energy systems like solar panels use FIP gaskets.

Medical

Many medical devices feature FIP gaskets, including dialysis machines, oxygenators, heart pumps, and ventilators.

Military and Defense

Global positioning system components, radar systems, and missile guidance systems require durable, precise gaskets.

Mining

Mining equipment and vehicles use FIP gaskets.

Oil & Gas

Processing equipment, communication systems, and power generators are constructed with durable FIP gaskets for oil and gas exploration and processing.

Petrochemical and Deep Sea

Many devices used in marine, petrochemical, and deep sea environments require leak-proof seals.

Robotics

FIP gaskets protect sensitive electronic systems from dust and also provide EMI shielding.

Mass transit

Doors, windows, seating, and mechanical systems all feature FIP gaskets in their construction.

Unmanned Aerial Vehicles (UAVs)

FIP gaskets protect against rigorous flight conditions and EMI by sealing antennas, avionics, airframes, and more.

The Future of Industrial Sealing

Since FIP gasketing is compatible with many high-performance materials and can seal even small or complex shapes, it holds a lot of potential for emerging industrial sealing applications. Looking to the future, new material options, smart sensor technology, and microgasket designs are expected to play an increasingly important role.

Advanced Materials

As a leader in quality and innovation, H&S monitors the latest advancements in FIP gasket manufacturing closely. As demand for these products grows, new materials are being explored to improve their performance capabilities. The next generation of FIP gaskets will feature materials with greater resistance to environmental stressors, like extreme temperatures and chemicals. Advanced materials will not only provide more effective sealing capabilities but also increase product lifespan.

As sustainability continues to be a key concern for future manufacturing, researchers are developing recyclable FIP gasket materials that will help companies reduce their carbon footprint.

Miniaturization

Industries like electronics and robotics are producing increasingly compact devices. This raises the demand for micro gaskets to reliably seal components on a very small scale. Miniature gaskets are needed to seal the narrow spaces within small assemblies while also providing a leak-proof EMI shield. Form-in-place gaskets have the potential to meet these demands.

Smart Gaskets Embedded With Sensors

A quickly growing trend within the FIP gasket field is the integration of sensor technology. When embedded into a gasket, smart sensor technology can provide real-time data on factors like:

System performance
Predictive maintenance
Temperature
Pressure
Vibrations

Monitoring this data allows for emerging problems to be resolved proactively, preventing costly system failures and unexpected downtime. Smart gaskets are expected to be widely used throughout industries like energy, aerospace, and manufacturing.

Automated, Precision Application

Automated technology is an important aspect of the FIP gasket deposition process. Leading manufacturers like H&S offer automated tools to deposit gasket materials precisely. For example, we use a 3-axis robot to accurately and consistently apply FIP gaskets in complex patterns. Automating application not only streamlines the production process but also ensures more consistent results and better product performance. Advanced CNC manufacturing tools eliminate human error, reduce lead times, and deliver more efficient, higher-quality results.

Sustainable Solutions

Due to the lack of waste materials FIP gasket manufacturing generates, it’s already an eco-friendly practice. However, with sustainability growing as a global priority, leading manufacturers are looking for new enhancements. The next generation of FIP gasket materials is set to be recyclable or even biodegradable without sacrificing performance.

Energy-saving manufacturing technologies are also being explored. Renewable energy sources are capable of powering production with lower operational costs and a reduced carbon footprint. These savings ultimately make FIP gaskets more affordable for businesses. With these new manufacturing capabilities on the horizon, the FIP gasket market is expected to experience continued growth and improved performance.

FIP Liquid Gasketing at H&S Manufacturing

Form-in-place gaskets are a versatile, high-performance sealing solution compatible with many demanding industry needs. At H&S Manufacturing, we offer custom FIP gasket dispensing for fields like robotics, EVs, UAVs, and many others. We use silicone-based materials in beads as small as .030 in. x .030 in. for precision positioning on even the most challenging substrates.

H&S Manufacturing is ISO 9001:2015 and AS9100 certified and manufactures FIP gaskets in prototype to production quantities. Contact our team with any questions, or request a quote today to get your next project started.

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