A European LED lighting manufacturer required a gasket for a new marine lighting unit being installed across a fleet of ships. The gasket needed to withstand saltwater exposure, UV radiation, and extreme offshore conditions, while maintaining a reliable seal around the enclosure.
Initially, the customer requested the softest available solid silicone, kSil™ GP40, for the perimeter gasket. However, due to the intricate geometry and tight tolerances, the part proved difficult to punch, resulting in high scrap rates and inconsistent edges.
Challenge
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Need for a durable, IP-rated seal for a marine lighting enclosure
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High resistance required to salt, UV, ozone, and temperature extremes
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Geometry caused punching difficulties in GP40 solid
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Cost increases due to waterjet cutting
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Requirement for future replacement gaskets for fleet maintenance
Solution: Switch to QR400 Closed-Cell Sponge
During development, it was suggested that a firmer sponge might meet the sealing requirements while improving manufacturability. We trialled QR400, a closed-cell silicone sponge with excellent compression and environmental resistance.
Why QR400 Worked
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Closed-cell structure delivers strong water and dust sealing for marine environments
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High UV, salt, and ozone resistance, ideal for offshore lighting
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Better compressibility than solid GP40, ensuring an even seal
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The material could be punched in-house, eliminating the need for costly waterjet cutting
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Improved consistency and lower production costs
The customer approved the QR400 gasket after successful trials and moved forward with production and replacement units.
