CapabilitiesRubber Compression
and Injection Molding
Gasket Fabrication and
Sheeted Materials
Molded Silicone Foam
and Sponges
Rubber Gasket and
Seal Support Services
Rubber and Elastomer Certified Testing5 Axis Water Jet Cutting

Sample WorkSilicone Rubber Exit
Door Seal
Compression Molded
Hydraulic Clamp Block
Compression Molded
Insulation Flange Seal
Compression Molded
Rubber Seal Assembly

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Silicone Rubber Exit Door Seal for the Aerospace Industry

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Silicone Rubber Exit Door Seal for the Aerospace Industry

Cascade Gasket assisted in the design and then manufactured this flight critical exit door seal for a commercial aircraft. The seal effectively blocks both air and water from the aircraft’s interior, in flight and while grounded, and is composed of three materials: BMS 1-57 silicone rubber, D2000 inter-weave fabric, and inconel metal inserts at the top of the seal. Although rubber compression molding was the primary manufacturing process, several steps were involved in creating the door seal.

First, the inconel metal inserts were pre-fabricated and coated, in preparation for receiving the rubber and fabric. Next, the part was hand formed and laid in the mold in four separate sections, blending together only at areas indicated by the print design. The mold was then placed under extreme heat and pressure for 4 hours, allowing the rubber to flow and fill the mold, assuming the shape of the final component, with a final tolerance of +/- 0- .030”.

After the molding was complete, the part was cleaned and placed in an oven for 3 hours at 350 degrees Fahrenheit, to set the shape and cure the rubber. The final process involved the addition of a secondary seal, applied on the header section of the seal, for extended sealing and management of the product. The final exit door seal is both air and water tight, and measures 48” long by 27” wide.


Product DescriptionFlight Critical Exit Door Seal for a Commercial Aircraft
Capabilities Applied/ProcessesRubber Compression Molding
Overall Part DimensionsLength: 48", Width: 27"
Tightest Tolerances+-.030
Material UsedSeal: BMS 1-57 Silicone Rubber, D2000 Interweave Fabric

Inserts: Inconel

FeaturesAir Tight, Water Tight
Mold Procces TypeCompression Molding
Typical OperationsCompression Molding:
Part Laid Up in Four Separate Sections
All Parts Blend Together at Customer Specified Areas
Completely Hand Formed and Laid Into Mold
Mold is placed Under Pressure and Heat for 4 Hours
Placed in Oven and Heated to 350˚F for 3 Hours
This Process Sets the Shape and Cures the Rubber
Secondary Seal is applied to Header Section using the Bonding Process
In process testing performedNone
Industry for UseAerospace
Standards MetCustomer Supplied Engineered Print
Product NameDoor Seal
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