Introduction
For decades, Rogers’ HT-800 series silicone foams have been the benchmark for lightweight, durable gasketing materials. But what if you need a silicone sponge alternative with comparable compression, sealing, and thermal stability? Enter the RS-800 series: RS-800, RS-820, RS-840, and RS-870.
These materials are engineered to provide the same balance of softness, resilience, and temperature resistance—while offering cost-effectiveness and reliable supply outside of the Rogers catalog.
Product Lineup at a Glance
| Grade | Density / Firmness | Relative Firmness | Common Equivalent | Standard Thicknesses |
|---|---|---|---|---|
| RS-800 | Medium Density- Still Soft | Medium Firmness | HT-800 | 0.125″ to 0.500″ (0.8–12.7 mm) |
| RS-820 | Medium-firm density | Semi-firm | HT-820 | 0.063” to .625” |
| RS-840 | High density | Extra-firm | HT-840 | 0.125″ to 0.188″ (3.175–4.7752 mm) |
| RS-870 | Low Density | Extra-Soft | HT-870 | 0.125″ to 0.250″ (3.175–6.35 mm) |
All grades are supplied in sheets, rolls, and custom die-cut gaskets, making them true drop-in replacements for designs already built around HT-series materials.
Key Properties
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Closed-cell silicone sponge structure → Excellent resistance to water, dust, and air leakage.
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Wide operating temperature range (-55 °C to +200 °C typical) → Withstands extreme environments.
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UV, ozone, and weather resistance → Long-term outdoor durability.
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Low compression set → Maintains long-term gasketing performance.
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Flame resistance → Meets many UL and ASTM requirements for flame and smoke safety.
Applications
The RS-800 series, like HT foams, is widely used in:
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Electronics enclosures – environmental sealing and gap filling.
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Aerospace & defense – lightweight gasketing with high durability.
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Transportation (rail, EV, heavy equipment) – vibration damping, sealing against dust/water ingress.
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Lighting enclosures & HVAC – weatherproof sealing and insulation.
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General gasketing & cushioning – anywhere a reliable silicone sponge is needed.
Why Consider RS-800 Over HT-800?
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Direct equivalence – RS grades match HT grades in firmness and density.
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Performance parity – Both offer thermal stability, UV/weather resistance, and closed-cell sealing performance.
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Availability & cost – RS-series can be a more economical option without compromising function.
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Design flexibility – Always available as custom die-cut gaskets to fit exact design requirements.
Selecting the Right RS Grade
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RS-800 (Medium): Ideal for delicate sealing where low closure force is critical.
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RS-820 (Medium-firm): Good balance of compressibility and sealing strength.
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RS-840 (Firm): For applications needing higher compression force and better mechanical support.
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RS-870 (Soft): Best for super low closure pressure.
Conclusion
The RS-800 series (RS-800, RS-820, RS-840, RS-870) gives engineers a reliable, silicone sponge alternative to Rogers’ HT-800 family. With standard sheet thicknesses and the ability to supply precisely die-cut gaskets as the default, the RS-series delivers the same thermal, mechanical, and environmental benefits—often with added cost efficiency.