In industries where reliability and cleanliness are paramount—such as aerospace, defense, electronics, and medical devices—the risk of foreign object debris (FOD) is never taken lightly. A single loose particle, shaving, or improperly selected material can jeopardize equipment performance and safety. Gaskets play a surprisingly important role in preventing FOD by sealing out contaminants, securing assemblies, and ensuring long-term durability under demanding conditions.
At NEDC, we frequently see customers turn to silicone rubber, Poron®, silicone foam, and silicone sponge for FOD-critical gasket applications. Each of these materials has unique properties that make them well-suited for environments where preventing debris is as critical as sealing performance.
Silicone Rubber Gaskets
Silicone rubber is a top choice for FOD-prevention gaskets due to its inert chemistry, low outgassing, and clean machining behavior. Unlike lower-grade elastomers that can crumble or shed particles, silicone rubber die-cuts cleanly and maintains dimensional stability over time.
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Advantages: Wide temperature resistance (-60°C to 200°C), excellent UV and ozone stability, minimal particulate generation.
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Applications: Aerospace panels, electronics housings, and enclosures where both environmental sealing and cleanliness are required.
Because of its smooth, non-flaking surface, silicone rubber is a trusted solution when particle generation could cause downstream reliability problems.
Poron® Polyurethane Gaskets
Poron®, a microcellular polyurethane foam, is widely used for shock absorption, cushioning, and gasketing in electronics. Its fine cell structure resists crumbling and particle shedding, making it an ideal candidate where FOD concerns are high.
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Advantages: Excellent compression set resistance, low particulate generation compared to other foams, wide range of thicknesses (as thin as 0.010”).
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Applications: Smartphones, servers, aerospace electronics modules, and other assemblies where clean compression and vibration dampening are needed.
Poron® also offers predictable compression force deflection, which ensures long-term performance without generating debris inside sensitive devices.
Silicone Foam Gaskets
Silicone foam combines the stability of silicone chemistry with a closed-cell or semi-closed-cell structure, providing both sealing and FOD protection. Unlike urethane foams that can break down and shed over time, silicone foam maintains integrity under stress and exposure.
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Advantages: High resiliency, excellent flame resistance (often UL 94 V-0 rated), weather resistance, minimal crumbling under compression.
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Applications: Aircraft interiors, battery compartments, outdoor enclosures, and sealing applications where flammability, UV exposure, and cleanliness are factors.
Silicone foam can be supplied with PSA (pressure-sensitive adhesive) liners for easy assembly, while still avoiding adhesive residue issues that might contribute to FOD.
Silicone Sponge Gaskets
Silicone sponge differs from foam in that it has a more uniform, closed-cell structure created through extrusion or molding. It provides excellent sealing properties with the added benefit of being lightweight and resistant to mechanical breakdown.
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Advantages: Consistent compression characteristics, weatherability, resistance to tearing or fragmenting under load.
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Applications: Aerospace gaskets, cleanroom equipment, rail and transportation systems, and electrical housings where both debris control and long-term resilience are important.
Because it does not powder or flake the way some organic sponge materials can, silicone sponge offers a particle-free solution in high-reliability assemblies.
Why Material Choice Matters for FOD Prevention
The wrong gasket material can create more problems than it solves. For example, low-grade foams may crumble under compression, shedding particles into sensitive electronics or fluid systems. By selecting materials like silicone rubber, Poron®, silicone foam, and silicone sponge, engineers ensure that their gaskets not only provide the expected sealing function but also uphold FOD prevention standards.
At NEDC, we routinely die-cut, waterjet cut, and convert these materials into custom gaskets tailored for mission-critical applications. Whether the requirement is a thin dust seal for electronics or a thick, resilient barrier for aerospace assemblies, our team ensures the right material is chosen to prevent FOD at every stage.