Everything You Need to Know About Foam Gaskets

Gaskets are essential components in countless industries so that surfaces are sealed, vibrations are dampened and liquids or gases don't escape. In particular, foam gaskets have become a preferred choice in modern engineering and manufacturing due to their unique properties.

In this guide, we explain why foam is an excellent gasket material, how it works and the industries that benefit most from it.

What Are Gaskets and How Do They Work?

A gasket is a flexible component inserted between two surfaces to create a seal. They are used for several purposes:

• Preventing leaks of liquids, air, or gases
• Reducing vibration or noise
• Minimising fluid loss in mechanical systems
• Aiding the sealing process under high pressure or extreme conditions

Gaskets work by compressing between surfaces, creating an airtight or liquid-tight barrier. This compression allows the gasket to maintain an effective seal while also acting as an anti-vibration or noise-reducing component.

What Materials Are Gaskets Made From?

Gaskets can be made from a wide range of materials, each chosen for specific practical or economic reasons:

• Metal (copper, stainless steel) – High pressure and high-temperature applications
• Rubber and Silicone – Flexible, chemical-resistant, commonly used in automotive and plumbing
• Paper or Cork – Cost-effective, suitable for light-duty sealing
• Foam (EPE, XPE, Plastazote®) – Lightweight, durable, resistant to chemicals and vibration

The material choice depends on:

• Chemical resistance – Must withstand oils, fuels, acids, or cleaning agents
• Temperature tolerance – Survives high heat or sub-zero environments
• Pressure resistance – Effective in high-pressure or deepwater applications
• Industry requirements – Aerospace, automotive, food & beverage, petrochemical, and pharmaceutical

Why Foam Is an Excellent Gasket Material

Foam, particularly closed-cell foams like EPE, XPE and Plastazote®, offers several benefits over traditional gasket materials:

1. Chemical Resistance

Foam gaskets such as ZOTEK® N resist a wide range of chemicals, oils, fuels and antifreeze fluids. This makes them ideal for automotive, petrochemical and pharmaceutical applications where durability and reliability are crucial.

2. Anti-Vibration Properties

Excessive vibration can damage machinery or compromise safety. Closed-cell foams absorb and dampen vibrations, making them ideal for aerospace, aviation and automotive industries.

3. Precision Forming

Modern manufacturing often requires intricate gasket designs with tight tolerances. Foam gaskets can be precision-cut or shaped to meet exact requirements using advanced processes such as:

• CNC Routing and Machining
• Waterjet Cutting
• Moulding and Forming
• Splitting and Skiving

This flexibility ensures optimal performance in demanding applications.

4. Lightweight and Durable

Closed-cell foams are not only lightweight but also resistant to compression so that gaskets maintain their shape and function over time, even under constant pressure or vibration.

Industries That Rely on Foam Gaskets

Foam gaskets are used across a wide range of sectors, including:

• Automotive – Seals, vibration dampeners, engine components
• Aerospace & Aviation – Lightweight, vibration-resistant gaskets for aircraft components
• Pharmaceutical & Medical – Chemical-resistant seals for sensitive equipment
• Petrochemical & Oil & Gas – Corrosion and chemical-resistant seals
• Food & Beverage Manufacturing – Hygienic, chemical-resistant sealing solutions

By selecting the right foam material, businesses can improve safety, efficiency and product longevity.

Polyformes' Expertise in Foam Gaskets

At Polyformes, we specialise in designing custom foam gaskets, plugs and spacers using industry-leading materials like EPE, XPE, ARPLANK and Plastazote®. Our services include:

• Bespoke foam cutting and shaping
• Laser etching and branding options
• Precision foam inserts for machinery and tools
• Sustainable foam options with recycled content

Find out how our foam solutions can protect your equipment, reduce vibration and improve operational efficiency.

Explore Foam Gaskets

Foam gaskets offer a unique combination of chemical resistance, anti-vibration properties and precision formability, making them ideal for modern industrial applications. Whether you're in automotive, aerospace or medical manufacturing, the right foam gasket can improve performance, safety, and longevity of your equipment.

Contact Polyformes today to discuss your bespoke foam gasket requirements and discover a solution tailored to your industry.