Custom Gaskets- Waterjet Cut, Die-Cut

r10404, silicone, g10, polyetyhlene foam
assortment of different custom gaskets

New England Die Cutting(NEDC) manufactures gaskets of all sorts, sizes, colors, and materials. Gaskets are a generic term for something that seals out medias such as fluids, gases, dust or other harmful medias. Considering that, gaskets can refer to a lot of different end products. When NEDC got started in 1982, custom gaskets were its first product line. For that reason, NEDC is very experienced in the gasket business, equipping itself with countless machines that cut materials into unique custom shapes.

Customability of Gaskets

At NEDC our philosophy is that we are here to do what the customer wants. With gaskets, the ability to customize gaskets seems to never end. While not everything can be customized with another customization, the point is many different options are available. With countless applications ensuring that each gasket fits our customers needs is a priority. Material, thickness, color, durometer, or specifications, all can be changed to yield a custom gasket.


With gaskets, color customization is not uncommon. We have seen green gaskets, yellow gaskets, blue gaskets, and everything in between. Oftentimes we have customers who want a gasket a different color to see if it has been replaced already or if its a different revision. Some gasket materials are able to dyed different colors, others require minimum runs, and others cannot be.

Thickness/Thickness Tolerances

Thicknesses with gaskets range from .005” to 2.00”. In addition, thickness tolerances are constantly being tightened by our customers. We have seen gasket thickness tolerance as low as +/- .001” be achieved on select thicknesses of material.


Softness and hardness come down to something called durometer. Gasketing materials can be customized to meet certain durometer requirements. Different compression requirements are required in each application so being able to customize this feature is important. This may also include sponge/foam gasketing materials.


Specifications allow customers to get what they want on a repeatable basis. To list some specifications available are: AMS-R-25988, AMS-3323, A-A-59588, ZZR765, MIL-R-6855, AMS-3260, MIL-R-900, the list goes on and on. In the aerospace, military manufacturing space, military specifications are endless. However when making gaskets; everyday there seems like there is a new specification that comes out that requires a different material.

Solid Rubber Gaskets

Solid Rubber Gaskets refer to gaskets made out of solid rubber materials. There are countless of solid rubber materials to chose from. There are electrically conductive(EMI) options, fluid resistant options and more. Some common rubber materials include:






silicone gaskets

These gaskets are die-cut, waterjet-cut, and laser-cut. These gaskets are available in sizes ranging from .050’’ to 14 feet in length.  Commonly known solid rubber products include materials from OEMs such as Rogers, and Saint Gobain. In our current industry, solid silicone rubber products are extraordinary popular. These include CHR 9030, 9040, 9050, and 9060.

VHB Tape Gaskets

VHB Gaskets refer to VHB Tape materials provided by 3M cut into shapes that offer gasketing solutions. They are used in place of permanent fasteners. The time saved in assembly and processing can be dramatically cut down with VHB. The reason these acrylic foam tapes are used is because they offer great permanent bonding strength. In addition, they can seal out many mediums such as dust or water when properly applied. These tapes are commonly used on computer like tablets. These acrylic foam tapes include ultra thin and thick options to accommodate different applications. There are countless families of VHB Tapes to chose from. The main VHB Tape families are 4941, 5952, and RP Tapes.

Sponge/Foam Gaskets

Sponge/foam gaskets include cellular products that allow for less compression force. It is normally required to have significant pressure to seal out different medias properly. These materials have been chemically, or otherwise expanded. However, they are commonly made out of the same base materials as many solid rubber gasketing options. Some examples of foam/sponge gaskets include silicone sponge, fluorosilicone sponge, neoprene sponge, PORON®(urethane foam), or sponge blends. Sponge and foam gaskets are highly customizable. Some examples of that include thermally conductive options, electrically conductive options, and ultra-soft/firm options.

Commonly known cellular foam/sponge products include:

Silicone Sponge Products such as NORSEAL® R10400, R10450, R10460, R10470, R10480, and R10490 by Saint Gobain Performance Plastics.

-PORON® Urethane Foams by Rogers Corporation. PORON® has a huge variety of thicknesses, densities, and firmnesses available for purchase.

Silicone Foam Products such as BISCO® HT-800, HT-820, HT-840, and HT-870 by Rogers Corporation.

-Electrically Conductive Products such as Condux Plus™ from Rogers.

-Thermally Conductive Products such as Thermacool R10404 from Saint Gobain.

Plastic Gaskets

There are times that gaskets are made out of plastic materials instead of elastomeric ones. Some materials used include PTFE(Teflon), Nylon, UHMW, G10 Epoxyglass, and more. These materials are cut out of flat sheet materials by NEDC. As a result, the plastic we cut is usually relatively thin due to the fact we are cutting through it with either a die, laser, or a water stream.

Tape Backings(Pressure Sensitive Adhesive)

With custom gaskets tape backings are available. These help with assembly. Many different types of peel and stick options are available. Oftentimes NEDC will apply acrylic pressure sensitive tape such as 3M 9472, or 9485PC. These high-performance acrylics stick well to most high-surface energy substrates. However, silicone pressure sensitive adhesive options are also available.

About NEDC

If you have an application that you believe could utilize a custom manufactured gasket, please contact

BISCO® & PORON® are registered Trademarks of Rogers Corporation.

NORSEAL® is a registered Trademark of Saint Gobain Performance Plastics.