The next decade in the development of military vehicles represents a shift in design. As we look towards 2026–2035, the distinction between an asset and a liability often comes down to the smallest components. While armour and firepower grab the headlines, the integrity of silicone seals remains incredibly important.
Here at Silicone Engineering, we develop the highest quality silicone formulations for application across multiple sectors, including the military.
Why sealing matters for next-gen platforms
Next-generation military vehicles will endure harsher environments, heavier payloads, and more sophisticated threats than before. Therefore, they need sealing solutions that protect their components (including their sensitive electronics) from several things, including:
- Water
- Dust, dirt and sand
- Grease
- UV exposure
- Mould and mildew
- Fluctuating temperatures
- Different weather conditions
- Chemicals
- Biological weapons
- Radioactive material
- Nuclear material
A silicone seal also prevents leaks and keeps different parts of the vehicle separate from each other.
Mission profiles, threat environments and vehicle trends
The threat landscape for the future is characterised by unpredictability – mission profiles are shifting from static counter insurgency to high-tempo, multi-domain operations.
Military vehicles could be deployed anywhere from the freezing Arctic to the searing heat of the desert and must be able to withstand both environments without modification. Next-generation engines and weapons generate immense heat, so silicone seals must be able to withstand higher operating temperatures while maintaining their elasticity. If the vehicle is deployed in a polar region, the silicone can’t become brittle in the plummeting temperatures.
The re-emergence of chemical and biological threats necessitates seals that are chemically inert. Wash-down procedures that use harsh decontamination agents can degrade inferior materials rapidly, whereas future-proof sealing must survive repeated exposure to fuels, hydraulic fluids, and decontamination chemicals without swelling, cracking, or losing compression set.
Silicone performance under extreme conditions
Silicone rubber is the material of choice for sealing because it’s generally non-reactive and resistant to extreme environments, stresses and temperatures. This stability is essential if the next-generation military vehicles are going to have a long lifespan. At Silicone Engineering, our team of experts work closely with you every step of the way to ensure all our silicone seals and gaskets are fit for purpose.
Temperature extremes and thermal cycling
Silicone maintains its mechanical properties across a huge temperature range, typically from -60°C to +230°C, with specialised grades extending even further. Importantly, it excels in thermal cycling. In aerospace applications, where a vehicle might ascend from a scorching runway to sub-zero altitudes in minutes, silicone seals will have to expand and contract without fatigue, and maintain a constant seal interface.
Vibration, shock and dynamic loading
Military vehicles are subjected to intense vibration, whether from rough terrain, rotor wash, or ballistic impact, and a rigid seal will fail under these conditions. Silicone’s inherent damping properties, on the other hand, not only seal well but also help isolate components from shock. Cellular (sponge) silicone grades are particularly effective here, offering excellent compression recovery. They absorb dynamic energy while maintaining the sufficient contact pressure to prevent ingress.
Fluids, fuels and environmental exposure
While standard silicone has limitations with certain hydrocarbon fuels, fluorosilicone (FVMQ) bridges this gap. It combines the temperature resistance of silicone with the fuel and oil resistance of fluorocarbons.
For exterior applications, silicone is virtually immune to UV radiation and ozone, meaning door seals and hatch gaskets won’t degrade or chalk even after years of exposure to direct sunlight.
Key applications on land, air and naval vehicles
Silicone’s versatility means it can be engineered for specific subsystems, regardless of the environment.
Hull, door and hatch sealing
The hull on armoured personnel carriers (APCs) and battle tanks has to remain watertight during deep wading operations. Large-format silicone profiles provide the necessary compression to seal heavy ramps and hatches. These seals must resist taking a set (i.e. permanently deforming) so that the hatch seals just as tightly on the 100th closure as it did on the first.
Electronics, sensors and communications enclosures
The digitisation of the battlefield means every next-generation military vehicle will be a node in a network. Lid seals for radios, radar units, and night-vision equipment require precise, low-closure-force gaskets. Conductive silicones loaded with metal particles (such as silver-aluminium) serve a dual purpose: they seal out moisture while providing EMI shielding to prevent signal jamming or detection, enhancing crew safety and communication.
Powertrain, exhaust and thermal management interfaces
Hybrid-electric propulsion will become more common in military fleets, which makes thermal management more complex. Silicone hoses and gaskets manage the flow of coolants and air between battery packs, inverters, and combustion engines. Their ability to resist high heat makes sure exhaust proximity doesn’t compromise the vehicle’s integrity.
Material choices for future-proof sealing
Selecting the right silicone grade and geometry
Not all silicones are created equal; engineers need to specify the correct density and hardness (Shore A). A seal that’s too hard will require excessive closing force, potentially warping the door or hatch. A seal that’s too soft might not provide the adequate pressure to prevent water ingress under blast overpressure.
The profile geometry is equally important; hollow profiles can offer high compression with low force, ideal for lightweight doors on airframes, while T-shaped gaskets provide interlocking seals, for example.
Balancing compliance, durability and maintainability
Maintainability is a key driver for programme managers, and seals that require frequent replacement put unnecessary burden on the logistics chain. High-consistency rubber (HCR) and cellular silicones offer exceptional longevity, often outlasting the component they protect. This “fit and forget” reliability reduces total cost of ownership and increases fleet readiness rates.
Working with Silicone Engineering on defence projects
Integrating with the military & defence portfolio
Silicone Engineering was one of the first pioneering companies to specialise in the manufacture and supply of silicone rubber for sealing across a wide range of sectors, with over 67 years’ experience. We provide silicone expertise and innovative custom solutions for defence projects, with all materials formulated and tested in our own laboratory.
Next steps for 2026–2035 vehicle programmes
The design decisions made today will dictate the operational capability of armed forces and the future of the military well into the 2040s. Sealing can’t be an afterthought.
By prioritising advanced silicone materials that offer thermal stability, chemical resistance, and dynamic resilience, programme managers can make sure their platforms are robust, reliable and ready for whatever the future battlefield holds.
Contact the team at Silicone Engineering to discuss upcoming vehicle platforms and sealing specifications, and don’t forget to explore our full news archive.