At NEDC, we specialize in die cutting and fabricating custom gaskets from advanced materials. One of the most effective and versatile options we frequently work with is oriented wire gasket material, which features embedded wire strands within silicone, fluorosilicone, or silicone sponge rubber. These high-performance custom gaskets provide both EMI shielding and environmental sealing, making them ideal for demanding applications in aerospace, military, telecom, and industrial electronics.
What Are Oriented Wire Custom Gaskets?
Oriented wire gaskets are composite materials that consist of fine conductive wires embedded at 90 degrees to the plane of the elastomer. This unique orientation enhances EMI shielding capabilities while maintaining excellent compressibility for environmental sealing.
These materials are originally manufactured in large blocks and then sliced into sheet or strip form. At NEDC, we convert these sheets into precision custom gaskets using die cutting or waterjet cutting to meet exact application requirements.
Composition of Oriented Wire Custom Gaskets
1. Conductive Wire Options
The embedded wire is a key component for EMI shielding. We offer several alloy options, each selected for specific galvanic compatibility needs:
- Monel Wire – per QQ-N-281, AMS-4730 (.0045″ diameter)
- Aluminum Alloy 5056 – per AMS-4182 (.005″ diameter)
- SnPhBronze Alloy 30 – per ASTM B105 (.0045″ diameter)
These wires are securely cured into the elastomer to prevent dislodging during use or assembly.
2. Elastomer Options
The elastomeric component of the gasket serves as the environmental sealing layer, with several choices to match application performance requirements:
- Closed Cell Silicone Sponge – per AMS-3195 (Medium Density, Grey)
- Silicone Rubber – per A-A-59588 Class 2B Grade 40 (Grey)
- Silicone Rubber – per A-A-59588 Class 3A Grade 30 (Grey)
- Fluorosilicone Rubber – per MIL-R-25988 Type II Class 1 Grade 40 (Blue)
Available in thicknesses from .032″ to .188″, these elastomer options offer a range of compression profiles and durability levels for custom gasket design.
Partitioned Wire Custom Gasket Designs
Some custom gasket configurations use partitioned wire orientation, meaning the conductive wire is embedded only in a portion of the gasket—often half the width. This design allows one side to serve as the EMI shielding zone, while the other side acts as a weather/environmental seal. These hybrid custom gaskets are popular in applications where both sealing functions are needed in a compact profile.
PSA (Pressure-Sensitive Adhesive) Notes
It’s a common misconception that EMI gaskets must use electrically conductive adhesive. In fact, oriented wire gaskets typically do not require conductive PSA, as the embedded wires pierce through standard adhesive layers to maintain electrical continuity—similar to how embossed contacts work.
By avoiding conductive adhesives, designers can reduce galvanic corrosion concerns and improve material compatibility—especially when custom gaskets are applied to dissimilar metals.
Precision Fabrication of Oriented Wire Custom Gaskets
NEDC has extensive experience in converting oriented wire elastomeric materials into custom gasket components using high-precision die cutting or waterjet technologies. Whether you need EMI shielding, environmental sealing, or both, our team can deliver the right gasket solution for your application.
Contact Us
If you’re looking for a reliable partner for oriented wire custom gaskets, contact sales@nedc.com. Our team is happy to help you evaluate the right material, wire configuration, and gasket design to meet your technical and performance requirements.