BISCO BF-1000 & BF-2000: Low-Closure-Force Silicone Foams for Aerospace Electronics
Designing a gasket for an aerospace electronics enclosure is not simply about finding a material that seals the gap.
The gasket also has to work with the enclosure itself.
When an enclosure cover or housing is thin and lightweight, the force required to compress a gasket can become a significant part of the mechanical design. A material that requires excessive closure force may cause the cover to flex, distort the housing, or place unnecessary stress on fasteners and sensitive components.
This is where Rogers BISCO® BF-1000 and BF-2000 silicone foams can be worth evaluating.
Both materials are highly compressible cellular silicone foams designed for applications where softness, conformability, and low closure force are important. Rogers identifies BF-1000 as an extra-soft silicone foam and BF-2000 as an ultra-soft silicone foam, with both grades available for sealing, gap filling, cushioning, and vibration-management applications.
As a Rogers Preferred Converter, ABLE can help engineers evaluate BISCO materials and convert them into application-specific components through precision converting processes.
Why Gasket Closure Force Matters in Lightweight Enclosures
A gasket needs enough compression to create an effective seal, but the force required to achieve that seal is also important, especially when the enclosure is lightweight. Excessive gasket force can cause flexing or add stress to thin enclosure walls, covers, and hardware, so engineers need to consider the gasket material, gap, target compression, and enclosure design together. A low-closure-force silicone foam gasket can be a suitable option when the enclosure cannot tolerate the force required by a firmer material.
What Is BISCO BF-1000?
Rogers describes BF-1000 as suitable for sealing outdoor enclosures, electronics protection, cushioning, and vibration isolation. Its softness allows protective seals to be created with less closure force, while its compressibility allows the material to conform to variable-width gaps.
That combination can be particularly useful when an enclosure has:
- Variable or imperfect gaps
- Lightweight covers
- Sensitive internal electronics
- Limited available closure force
- Requirements for cushioning or vibration management
- Exposure to changing environmental conditions
BF-1000 is available in thicknesses from approximately 0.063 to 1.000 inches (1.59–25.40 mm), depending on the material configuration. Rogers lists a typical compression force deflection of approximately 1–5 psi and operating temperatures from -55°C to 200°C.
Its resistance to UV, ozone, and extreme temperatures also makes it suitable for demanding environments where long-term gasket performance matters.
Where BF-1000 Can Be Used
BF-1000 can be evaluated for applications where a soft, compressible gasket is needed without requiring the closure force associated with firmer foam.
Potential applications based on its characteristics include:
- Environmental sealing around aerospace electronics
- Gasket applications with variable or non-uniform gaps
- Cushioning around sensitive components
- Vibration isolation
- Lightweight enclosure sealing
- Aerospace electronics gasket applications where closure force is a concern
The final material selection should still consider the available gap, required compression, enclosure construction, and operating requirements.
What Is BISCO BF-2000?
If BF-1000 is designed around extra softness, BISCO BF-2000 takes low-closure-force performance even further.
Rogers describes BF-2000 as an ultra-soft, highly compressible silicone foam intended for applications where low closure force and sealing are critical.
Its high compressibility allows it to accommodate variable gaps while applying relatively low force to the enclosure.
That can make BF-2000 particularly interesting for lightweight aerospace and electronics designs where enclosure deformation is a concern.
Rogers lists BF-2000 with a typical compression force deflection of approximately 0–2 psi at 25% compression, compared with approximately 1–5 psi for BF-1000. The published material data also lists a temperature range of -55°C to 200°C and UL94 V-0 performance.
BF-2000 is available in thicknesses from approximately 0.125 to 0.500 inches (3.18–12.70 mm).
BF-2000 Applications
BF-2000 can be considered for aerospace electronics and other compact applications where low gasket closure force is an important design consideration.
Applications may include:
- Lightweight covers and housings
- Compact aerospace electronics
- Dust sealing
- Vibration isolation
- Variable-gap sealing
- Sealing around sensitive components
When evaluating BF-2000, engineers should consider the gap, target compression, available material thickness, and environmental requirements before finalizing the gasket design.
BF-1000 vs. BF-2000: What Is the Difference?
Both materials belong to the soft end of the BISCO cellular silicone range, but they are not interchangeable in every application.
A simplified comparison is:
| Property | BISCO BF-2000 | BISCO BF-1000 |
| Material type | Ultra-soft silicone foam | Extra-soft silicone foam |
| Relative softness | Softer | Slightly firmer |
| Closure force | Very low | Low |
| Typical CFD at 25% compression | 0–2 psi | 1–5 psi |
| Thickness range | 0.125–0.500 in | 0.063–1.000 in |
| Typical density | 10 PCF / 160 kg/m³ range | 12 PCF / 192 kg/m³ |
| Temperature range | -55°C to 200°C | -55°C to 200°C |
| Key consideration | Very low closure force | Balance of softness and conformability |
BISCO Silicone Foam for Aerospace Electronics
Aerospace electronics increasingly require compact, lightweight, and reliable packaging.
This creates a design challenge: the enclosure has to provide environmental protection without adding unnecessary weight or mechanical complexity.
Gaskets play an important role in that equation.
A properly selected silicone foam gasket can help protect electronics from contaminants while accommodating enclosure tolerances and mechanical movement.
Rogers’ BISCO material portfolio includes grades ranging from ultra-soft and extra-soft materials through medium, firm and extra-firm cellular silicones. This allows engineers to select a material based on the required balance of compression force, sealing, durability and application conditions.
BF-2000 and BF-1000 are therefore best viewed as part of a broader material-selection strategy, rather than simply as replacement gaskets.
BF-1000 vs. BF-2000 vs. HT-800
For engineers evaluating BISCO materials, comparing grades can help identify the appropriate starting point.
For example, BISCO HT-800 is a medium silicone foam that provides enhanced sealing capability compared with softer BISCO grades. Rogers lists HT-800 with a typical compression force deflection range of approximately 6–14 psi at 25% compression.
That creates a useful spectrum:
BF-2000 → BF-1000 → HT-800
From very low closure force toward greater firmness and sealing force.
The appropriate choice depends on the application.
If a thin enclosure cannot tolerate significant gasket force, BF-2000 or BF-1000 may be worth evaluating.
If greater firmness and sealing performance are required, HT-800 or another BISCO grade may be more appropriate.
This is why gasket selection should be based on the complete application rather than simply choosing the softest available material.
How ABLE Helps Convert BISCO Silicone Foam
To make a gasket suitable for aerospace use, one must not only choose a high-performance material, but may also require adhesive backing, bonding, accurate cutting, inspection, and configuration. ABLE supports the Rogers materials BISCO FPC, HT-800, BF-1000, and BF-2000 in conjunction with the material, adhesive, and fabrication process. ABLE can also provide assistance with samples, option conversion, prototypes, and thickness, tolerances, adhesive construction, and gasket geometry. These details are important to make sure that the gasket design is feasible and well-suited for production.
Why Work With a Rogers Preferred Converter?
The use of a converter who has worked with Rogers BISCO before will assist the engineer in meeting the material and fabrication requirements prior to finalizing a design. ABLE has been certified to the AS9100D standard and is ITAR registered, and routinely uses Rogers BISCO materials in aerospace and defense. The team can help you with material selection, adhesive construction, fabrication, samples and prototypes, and material availability. It is easier to assess the material and converted construction if the converter is engaged early.
BISCO BF-1000 and BF-2000 provide silicone foam options for aerospace electronics where low closure force and compressibility are important. BF-1000 is an extra-soft option for sealing, cushioning, and vibration isolation, while BF-2000 is an ultra-soft option for applications requiring very low closure force. Compared with HT-800, these softer materials may be considered when lightweight enclosures or sensitive components make gasket force important. With experience converting Rogers BISCO materials, ABLE can help engineers move from material selection to prototypes and finished gasket configurations for aerospace and defense applications.
Contact ABLE today to explore the right BISCO silicone foam material and custom converting solution for your aerospace application!
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