Prototyping and Testing Sealing Solutions

At Gallagher Fluid Seals, engineering is central to every project and solution we deliver.  Our goal is to provide sealing solutions where there had been sealing failures, and our engineering team is among the most experienced and talented in the industry.

This is the third in a four-part series discussing how we work with our customers to create a sealing solution for their most critical applications.  So far, we’ve talked about Application Discovery & Review and Commercial Evaluation & Development.  The third step in this process is Prototyping & Testing.

Depending on the nature of the part, the first run of prototype parts will be developed for evaluation and testing purposes using a single or low cavity tool.  With advances in on-demand manufacturing technology, some seal manufacturers now offer rapid prototyping or “express” services, where prototypes can be machined or 3D printed to exacting specifications.  This lowers mold and tooling cost while usually providing a faster turnaround time.

We realize testing resources are usually limited, and recreating operating conditions can be tough. Fortunately, GFS can facilitate 3^rd party testing, either by one of our trusted suppliers, or by an accredited laboratory or testing facility.  We then need to work together to develop criteria for testing and evaluation, which is paramount.  This is a good time to revisit our application discovery and review section and ask ourselves “why are we incorporating a new sealing element?”  The key is to fix the original problem we discussed in Step 1.

Part of testing sealing solutions will undoubtedly include accelerated failure testing, where environmental stresses are applied to push the sealing element to its absolute limits in a short period of time, eventually reaching a level significantly beyond what is expected during use.  By finding design weaknesses early and making changes, we can lower product development costs and compress time to production.

The final check will be material compatibility.  If there are issues with testing, is the problem the mechanical design or the material being used?  After seeing the first round of test results, are there any other materials we should test that might yield better results?  Once all testing has been completed and reviewed by the Gallagher Engineering Department, we move on to the approval and production stage.

 This is the third step in getting you the BEST seal for your product or application.  Continue reading our blog for the subsequent parts of this blog series, “Designing a Sealing Solution.”

 Part I: Application Discovery & Review

Part II: Commercial Evaluation & Development

Part III: Prototyping & Testing

Part IV: Approval & Production