BISCO® HT-800 for Aerospace and Defence: Long-Term Environmental Sealing for Demanding Applications
When designing a gasket or seal for aerospace and defense equipment, passing an initial leak test is only part of the challenge.
The real question is whether that seal will continue to perform after months or years of compression, vibration, temperature changes and exposure to the elements.
For enclosures protecting sensitive electronics and other critical components, a gasket needs to maintain contact with the mating surfaces over time. It must accommodate variations in the assembly while resisting environmental conditions that can cause conventional sealing materials to deteriorate.
BISCO® HT-800 medium cellular silicone foam from Rogers Corporation is designed for applications where long-term sealing performance, durability and environmental resistance are important. Its medium-firm construction combines the lightness of a foam with enhanced sealing capabilities, while its memory and low stress relaxation help reduce the risk of gasket failure associated with compression set and softening.
For aerospace and defense manufacturers, ABLE converts BISCO® HT-800 into custom gaskets and sealing components designed around the specific dimensions and requirements of an application.
What Is BISCO® HT-800?
BISCO® HT-800 is a medium-firm cellular silicone foam manufactured by Rogers Corporation.
It is designed to bridge the gap between softer, highly conformable foams and firmer, more durable sealing materials. According to Rogers, HT-800 combines the lightweight characteristics of foam with enhanced sealing capabilities similar to traditional sponge rubber.
The material is particularly suited to applications requiring:
- Environmental sealing
- Protection against fine particles
- Resistance to wind-driven rain
- Shock reduction
- Vibration isolation
- Long-term compression performance
- UV and ozone resistance
- Flame resistance
- Performance across a wide temperature range
Rogers lists HT-800 in thicknesses from 0.031 to 0.500 inches (0.79 to 12.70 mm), with a typical density of 22 PCF and a compression force deflection range of 6–14 psi.
This range gives engineers flexibility when designing seals for different enclosure geometries and compression requirements.
Why Long-Term Sealing Performance Matters
Over time, seals may be subjected to consistent compression, temperature variation, vibration, and exposure to the environment that could impact contact reliability over time. BISCO® HT-800 has been developed to have good compression recovery and low stress relaxation, which enables the material to keep its shape and sealing property after repeated compression. This extended performance can help safeguard critical aerospace and defense parts and contribute to the reliability and longevity of the assembly.
What Makes HT-800 Different From Softer Silicone Foams?
Not every sealing application requires the softest possible foam.
In fact, choosing a material solely because it is soft can create other design challenges.
A softer foam may conform easily to irregular surfaces, but the enclosure must still provide enough compression to create and maintain an effective seal.
HT-800 takes a medium-firm approach.
Rogers lists a typical compression force deflection of 9.7 psi at 25% deflection, within a specified range of 6–14 psi.
This means engineers need to consider the relationship between the gasket and the enclosure.
The design must provide enough compression to create a seal without generating excessive force that could:
- Bow an enclosure
- Distort mating surfaces
- Overload fasteners
- Damage sensitive components
- Increase assembly difficulty
In other words, the best gasket material is only effective when the entire sealing system is designed correctly.
BISCO® HT-800 for Aerospace Enclosures
Aerospace and defense enclosures safeguard delicate electronics, electrical systems, communication equipment and other critical components from harsh environmental conditions. BISCO® HT-800 can be employed in gasket applications to assist in forming an impervious barrier to temperature, vibration, dust and moisture. The material’s cellular structure ensures that it will compress against mating surfaces, and its resistance to UV and ozone helps ensure long-term performance. Once it is precisely converted to the shape and size desired, HT-800 can be utilized as a custom gasket, seal or cushioning part for aerospace and defence enclosures.
How Does Silicone Foam Help With Environmental Sealing?
Silicone foam is particularly useful when a gasket needs to balance flexibility, resilience and environmental durability.
A cellular silicone structure can compress to accommodate surface irregularities while recovering after compression.
This makes silicone foam useful for creating a controlled sealing interface between two surfaces.
For an enclosure, the basic principle is straightforward:
Enclosure + gasket + controlled compression = environmental barrier
However, getting that equation right requires careful consideration of the gasket’s:
- Thickness
- Width
- Shape
- Compression
- Compression force
- Surface contact
- Corner geometry
- Splices or joints
- Installation method
- Operating environment
This is where precision converting becomes particularly important.
BISCO® HT-800 for Vibration Isolation
During operation, transport or deployment, the sensitive electronic or mechanical components in the aerospace and defense equipment can be subjected to continuous vibration and mechanical shock. The cushioning properties of BISCO® HT-800 also help to reduce shock and isolate vibrations, and also contribute to environmental sealing. With vibration-management and sealing capabilities all in a single converted part, HT-800 can provide protection for critical assemblies and ensure equipment reliability.
ABLE’s Role in Custom BISCO® HT-800 Converting
Selecting BISCO® HT-800 is only the first step.
The material still needs to be converted into the right shape for the application.
As a Rogers Preferred Converter, ABLE can support customers in converting Rogers materials into application-specific components.
Rather than using a standard sheet or strip, manufacturers can work with ABLE to develop custom gasket configurations based on their enclosure geometry.
ABLE’s converting capabilities include:
Precision Die Cutting
Die cutting can produce repeatable gasket shapes with defined dimensions, openings and internal features.
This is particularly useful for enclosure gaskets that need to match a specific housing or component.
Slitting
Slitting can convert material into specific widths for applications requiring continuous strips or custom-width gasket material.
Laminating
Where the application requires multiple material layers, laminating can combine compatible materials to create a more integrated component.
Rapid Prototyping
Before committing to production quantities, engineers can evaluate prototype gaskets to confirm:
- Fit
- Compression
- Installation
- Alignment
- Sealing interface
- Enclosure closure force
This can help identify design issues earlier in the development process.
Assembly and Kitting
For manufacturers managing complex assemblies, ABLE can also support assembly and kitting requirements to help streamline downstream production.
Supporting Demanding Aerospace and Defense Applications
The materials used in the manufacturing of aerospace and defense equipment need to be exposed to high temperatures, vibrations, compression, and other extreme operating conditions. BISCO® HT-800 is a medium-firm, flexible, compression recovery, environmentally resistant rubber compound that can be used for sealing, cushioning, and vibration management. ABLE’s precision converting capabilities enable HT-800 to be converted to custom components that are designed to fit the dimensional and functional specifications. BISCO® HT-800 can be used to safeguard key aerospace and defense assemblies ranging from enclosure gaskets to vibration-isolation components.
Long-term environmental sealing is essential for aerospace and defense equipment exposed to temperature changes, vibration, compression, and other demanding conditions. BISCO® HT-800 offers a balance of firmness, flexibility, compression recovery, and environmental resistance for applications such as enclosure gaskets, environmental seals, cushioning, and vibration isolation. However, selecting the right material is only part of the process, as precise converting is also needed to meet specific dimensions, tolerances, and assembly requirements. With ABLE’s precision converting expertise, BISCO® HT-800 can be transformed into custom components designed to support reliable performance in demanding aerospace and defense applications.
Contact ABLE to discuss your sealing, cushioning, and flexible material component requirements!
References:
https://able123converting.com/blog/bisco-fire-protective-covering/
