Choosing the right sealing material is one of the most crucial decisions that engineers, designers, and procurement managers make. A profile’s performance, service life, and overall cost efficiency depend heavily on whether the material matches the demands of the application.
Three materials stand out in industrial sealing: rubber, silicone, and thermoplastic elastomers (TPE). Each has its own strengths and limitations. By understanding the differences, it becomes easier to select a sealing solution that ensures reliability and long service life in your environment.
Why Material Choice Matters in Sealing Solutions
Seals are small components with a big impact. The wrong material choice can lead to leaks, vibration issues, or premature wear. These failures increase maintenance costs and may cause downtime in critical industries such as construction, marine, railway, and heavy machinery.
Selecting the right sealing profile from the start reduces lifecycle costs and improves overall system reliability.
Rubber Seals: Durable and Cost-Effective
Rubber has long been a standard choice for seals because it combines durability with affordability. Rubber profiles are elastic, abrasion-resistant, and able to handle mechanical stress. They are widely used in construction, automotive parts, and general industrial machinery, where cost control matters.
The main limitation is sensitivity to weathering. Standard rubber can degrade when exposed to UV light, ozone, or extreme conditions. Its temperature tolerance is also more limited compared to silicone. For applications where performance under harsh environments is not required, rubber remains a practical and economical choice.
Silicone Seals: Resistant to Heat and Weather
Silicone provides reliable performance where rubber falls short. Its wide temperature range, from about –60 °C up to +200 °C, makes it suitable for demanding conditions. Silicone also resists UV radiation and ozone, which ensures flexibility even after years of outdoor exposure.
These properties explain why silicone profiles are widely used in the rail industry, marine environments, healthcare equipment, and food processing machinery. The trade-off is cost. Silicone is more expensive than rubber, and in some cases, it does not match rubber’s mechanical strength. Still, for long-term reliability in harsh or fluctuating environments, silicone is often the best option.
TPE Profiles: A Versatile Middle Ground
Thermoplastic elastomers, or TPE, combine rubber-like elasticity with the processing advantages of thermoplastics. This gives them a versatile role in sealing applications. TPE profiles are recyclable and provide a balance between performance and cost, making them attractive to many industries.
They are commonly used in transportation, building profiles, and consumer products. TPE is easy to customize and can be adapted to different designs, but it cannot match silicone’s resistance to extreme heat or chemicals. Companies that value both performance and sustainability often find TPE to be a strong alternative.
Key Factors in Choosing a Sealing Material
The right choice depends on the environment and requirements of each project. When comparing materials, decision-makers often consider temperature tolerance, chemical resistance, and the expected mechanical stress on the seal. Regulatory standards such as ISO, EN, or FDA requirements also guide the selection process. Increasingly, sustainability plays a role as companies look for recyclable materials and lower environmental impact.
Rubber vs Silicone vs TPE: Quick Comparison
| Property | Rubber | Silicone | TPE |
| Temperature range | Moderate | Excellent | Good |
| Weather resistance | Moderate | Excellent | Good |
| Flexibility | High | High | Medium–High |
| Cost efficiency | High | Medium–Low | Medium |
| Recyclability | Low | Medium | High |
Conclusion: Selecting the Right Material
There is no single “best” sealing material. The optimal choice depends on the environment, budget, and performance needs. Rubber offers durability and cost efficiency in everyday industrial use. Silicone excels under extreme temperatures and outdoor exposure, making it the material of choice for demanding conditions. TPE strikes a balance, offering flexibility and sustainability benefits that meet modern industry requirements.
By weighing performance, cost, and environmental considerations, companies can select the sealing material that provides both reliability and value.
At V.A.V. Group, we help our customers design and manufacture custom sealing solutions that perform in even the toughest applications. Contact our experts to discuss the best material for your project.
