Silicone in Military and Defence: Gaskets and Seals for Extreme Environments
Reliability is a non-negotiable in defence technology. Whether in a combat helicopter, an unmanned aerial vehicle (UAV), a submarine or an armoured vehicle, every component has to perform flawlessly, and often under the harshest conditions. Military hardware is routinely exposed to extremes of temperature, vibration, corrosive chemicals and potential fire hazards. These demanding environments call for materials that combine resilience, compliance and durability – qualities that define silicone rubber.
Unlike many other elastomers, silicone is engineered to meet military-grade performance. It can be formulated to comply with stringent specifications, making it one of the most trusted materials for gaskets and seals in defence systems.
Key performance requirements in defence sealing
Temperature extremes and flame resistance
Military equipment has to be able to withstand both the blistering heat of desert operations and the freezing cold at high altitude or underwater. Silicone rubber offers an exceptional operating temperature range, typically from -60°C to +230°C, maintaining flexibility and sealing performance where other rubbers fail.
Equally important is flame resistance. Silicones can be compounded to meet critical standards such as UL94 V-0 and AFS 1682A requirements, ensuring that gaskets and seals can maintain integrity during high-heat exposure and don’t contribute to the spread of fire.
Vibration, shock and environmental exposure
Defence platforms are subject to severe vibration and shock from the violent recoil of onboard weaponry and the constant turbulence of rotary aircraft. Silicone’s low compression set and inherent resilience ensure long-lasting sealing, even under repeated stress.
As well as this, silicone resists degradation from UV, ozone and weathering, making it suitable for outdoor and long-term deployment. Its resistance to fuels, lubricants and hydraulic fluids that are commonly encountered in military environments further demonstrate its value.
Applications of silicone gaskets & seals in defence
Aircraft and UAV systems
In aerospace applications, sealing components must cope with rapid altitude changes, sub-zero temperatures and aviation fire standards. Silicone gaskets are widely used in canopy seals, avionics enclosures and fuel system interfaces in both manned aircraft and drones. Their flame retardancy and resistance to jet fuel and hydraulic fluids make them mission ready.
Armoured vehicles and land equipment
Tanks, personnel carriers and other land vehicles need gaskets that perform despite constant shock, dust and exposure to fuels and oils. Silicone is often selected for hatch and door seals, engine bay gaskets and vibration-damping pads. In one case study, silicone sponge material was specified for use in an armoured vehicle floor system to reduce vibration levels for crew comfort while still meeting flame retardancy standards.
Naval vessels and subsea systems
Marine defence platforms – from destroyers to submarines – put unique demands on sealing materials. Silicone gaskets for hatches, sonar housings and control systems must resist both saltwater corrosion and extreme pressure at depth. Their ability to remain stable in humid, saline-rich environments makes silicone an ideal choice for long-term naval deployment.
Meeting military standards and specifications
Any silicone that is used in defence must comply with industry and military standards. Silicone compounds can be formulated to meet A-A-59588 and tested to MIL-STD requirements. Flame-retardant grades ensure compliance with aviation and marine safety standards, while closed-cell silicone sponge and solid grades are engineered for vibration control, EMI shielding integration and fluid resistance.
Here at Silicone Engineering, we’ve been working with silicone for over 65 years, so we know how to develop materials to the exacting specifications for military applications. This allows defence contractors to source sealing solutions that not only meet compliance but also deliver consistent performance in the field.
Enhancing mission reliability with Silicone
In the unforgiving world of defence technology, the margin for error is zero. Silicone rubber’s unique combination of temperature resilience, flame retardancy, vibration damping and environmental durability makes it a vital material for gaskets and seals across land, air and sea platforms.
For defence engineers and procurement specialists, silicone represents not just a material choice but a mission assurance strategy. With proven compliance to military standards and a track record in critical defence applications, Silicone Engineering provides the expertise to deliver sealing solutions that ensure safety, reliability and operational success.
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