Housing and cover with integrated seal

What are housing and cover with integrated seal?

Housings and covers with integrated seals are hybrid components in which the sealing element is firmly connected to the housing body or the cover. This is usually achieved by overmoulding, Vulcanisation or moulded insert. This creates a durable, ready-to-install unit that ensures both mechanical protection and the sealing of components. The principle is based on the combination of a metal or plastic housing with an elastic rubber sealing element, Silicone or TPE. While the housing provides stability, heat dissipation or protection, the integrated seal ensures media separation and tightness, even under pressure if designed accordingly.

Advantages over conventional solutions with separate seals:

No manual assembly of seals necessary
Error-free positioning and uniform contact pressure
Reduced leakage risks due to non-detachable connection
More compact design and lower unit costs for series production

This design is increasingly being used in technical systems where reliability, tightness and automation are paramount, such as in sensors, control units, pump housings or valve units.

Functions & applications of housings and lids with integrated seal

The housing and cover with integrated seal fulfil several tasks simultaneously and combine protective, sealing and structural functions in a single component. The combination of dimensionally stable and elastic materials creates a compact, reliable and easy-to-install solution with high safety and quality standards:

Sealing against liquids, gases and dust in accordance with defined IP protection classes (e.g. IP65-IP69K)
Mechanical protection of sensitive components against impact, dirt or corrosion
Pressure resistance in hydraulic or pneumatic applications
Vibration and noise damping thanks to elasticated Sealing elements
Compensation of tolerances between housing and cover
Easier installation and maintenance thanks to pre-assembled, durable sealing systems

Typical applications:

Electronics and sensor technology: housings for control units, plug connections or sensors
Vehicle technology: engine housings, covers, battery modules or light housings
Mechanical and plant engineering: pump, valve and hydraulic housings with integrated sealing function
Medical technology: sterile and pressure-tight housings with silicone seals
Energy and building technology: weatherproof junction boxes and covers for electrical systems

Components & materials of housings and lids with integrated seal

The choice of materials and joining technology determine the functionality and service life of housings and lids with integrated seals. The aim is to ensure a durable, elastic and media-resistant seal with simultaneous mechanical stability.

Metals:

AluminiumLightweight, corrosion-resistant, good heat dissipation
Stainless steelrobust, hygienic and chemically resistant
Steel: high strength, often coated, galvanised or nickel-plated

Plastics:

PA (polyamide): stable, temperature and chemical resistant
PBT (polybutylene terephthalate): dimensionally stable, electrically insulating
PP (polypropylene): lightweight, media-resistant, economical
PC (polycarbonate): impact-resistant, transparent, for visible enclosures
ABS: cost-efficient, good dimensional stability for indoor applications

Elastomer components for the integrated seal:

NBR (nitrile rubber): oil-resistant, suitable for hydraulic and machine applications
EPDMWeather, ozone and vapour resistant, for outdoor and water applications
Silicone (VMQ): high temperature resistance, flexible, hygienic and durable
FKM (Viton®): chemically resistant, for aggressive media and high temperature ranges
TPE (thermoplastic elastomers): recyclable, ideal for 2K injection moulding with plastic housings

To ensure that vulcanised housing components retain their sealing effect over the long term, they are designed to optimise assembly, sealing behaviour and stability:

Circulating Sealing lips or Sealing profiles, integrated directly into the cover or housing
Form-fit geometries to prevent detachment under compressive load
Ventilation or equalisation elements for pressure equalisation in the event of temperature changes
Rounded transitions for even pressure distribution and to avoid stress peaks

Further entries

Pressure resistance

Pressure resistance is the resistance of a material to compressive stress and is a decisive factor for the function and service life of technical components under mechanical stress.

Injection moulding

Injection moulding is a precise moulding process for manufacturing complex plastic and rubber parts in which the material is injected into a mould under pressure and cured there.

Mould cavity / cavity

Mould cavities are the cavities in a mould that give the component its final geometry during the moulding process.

Valves

Valves control, throttle or shut off liquids and gases in pipework, motors and hydraulic systems. They are crucial for process reliability and efficiency.

ABS: Acrylonitrile butadiene styrene

Acrylonitrile butadiene styrene (ABS) is a robust, impact-resistant and easy-to-process plastic that is used for housings, interior parts and rubber-plastic composite components with high surface and dimensional stability requirements.

Cold resistance

Cold resistance describes the ability of a material to remain functional and elastic at low temperatures - crucial for seals and elastomer components in outdoor or cold applications.

Autoclaves

An autoclave is a heatable pressure vessel for the thermal treatment of materials - e.g. for the post-vulcanisation of elastomers or for sterilisation in medicine and technology.

Elongation at break

The elongation at break indicates how much a material can stretch under tensile load before it tears.

Structural steel: S235 and S355

Structural steel (S235, S355) is a robust, easily weldable construction steel that is used as a stable carrier material in load-bearing structures, machine components and rubber-metal composite parts.

ISO 9001

ISO 9001 is the world's most important standard for quality management. It defines how companies manage their processes so that products and services deliver consistently high quality and fulfil customer requirements.

VMQ: Silicone rubber

Silicone rubber (VMQ) is a heat-, cold- and UV-resistant elastomer with very good insulation and media resistance, which is frequently used in medical, food and automotive technology.

Rubber buffers

Rubber buffers are elastic elements that absorb and dampen shocks, oscillations and vibrations. They protect machines, devices and assemblies from mechanical loads, compensate for movements and reduce noise in technical applications.

Azo and urea compounds

Azo and urea compounds are speciality chemicals that are used as blowing or cross-linking agents in rubber processing - especially for foams and friction-active components.

Extrusion of rubber

Rubber extrusion is a continuous manufacturing process for rubber-elastic profiles, hoses and seals in which the material is pressed through a moulding die and then vulcanised.

brass

Brass is an easily machinable, corrosion-resistant copper-zinc alloy that is widely used as a functional and decorative metal - including in rubber-metal composite parts, fittings and electrical components.

Calendering

Calendering is a rolling process in which rubber or plastic compounds are rolled between heated rollers. In addition to the manufacture of finished products such as rubber mats, it is primarily used in the production of rubber blanks.

Burr formation

Burr formation occurs in primary forming processes due to material escaping from mould parting surfaces and joints during forming and requires targeted reworking to ensure component quality.

Abrasion

Abrasion is the mechanically induced surface wear of a material caused by friction and has a decisive influence on the service life and usability of technical components.

Polyurethane (PU)

Polyurethane (PU) is a robust, abrasion-resistant plastic with high elasticity and chemical resistance, which is primarily used in heavily loaded technical components, dampers and composite solutions.

Vacuum cups

Suction cups are suction cups made of elastomer or plastic that cling elastically to the surface and trap the resulting vacuum. Suction cups create an adhesive connection between the gripper and the workpiece by means of negative pressure.

DIN ISO 3302-1

DIN ISO 3302-1 defines the general tolerances for moulded rubber parts and is an international standard for ensuring dimensional accuracy in elastomer processing.

PPA: Polyphthalamide

Polyphthalamide (PPA) is a dimensionally stable, chemical and temperature-resistant high-performance plastic that is used in particular for precise, media-resistant components and rubber-plastic composite solutions.

Sampling

In engineering, sampling is the testing and approval of sample parts of a new or revised product or manufacturing process.

Series production

Series production refers to the repeated, economical manufacture of similar components in large quantities.

NBR: Acrylonitrile butadiene rubber

Acrylonitrile butadiene rubber (NBR) is an oil and fuel-resistant elastomer that is frequently used for seals, hoses and technical moulded parts in mechanical engineering and vehicle construction.

Sealing lips

Sealing lips are flexible sealing elements that securely enclose media and remain reliably functional even in the event of rotation or pressure fluctuations.

Engine damper

Engine dampers are elastic elements that absorb vibrations and shocks between the engine and the vehicle or machine frame. They reduce vibrations, protect adjacent components from stress and improve the noise and running behaviour of the entire system.

Medical device regulation (MDR)

The Medical Device Regulation (MDR) is the central EU regulation for medical devices, which places high demands on safety, documentation and market surveillance.

Vibratory finishing (barrel finishing)

Mass finishing or barrel finishing is a mechanical mass finishing process in which surfaces are machined and burrs removed using abrasive media and movement.

Rubber blank

A rubber blank is a non-crosslinked, mouldable elastomer precursor that is processed in moulding tools to produce elastic rubber parts.

PC: Polycarbonate

Polycarbonate (PC) is a transparent, impact-resistant plastic that is used for high-quality housings, visible parts and functional composite components.

IRHD hardness (International Rubber Hardness Degree / ball indentation hardness)

IRHD hardness is an internationally standardised method for measuring rubber hardness using ball pressure and is particularly suitable for small or sensitive elastomer components.

Vulcanisation

Vulcanisation is the process in which raw rubber is converted into a permanently elastic, dimensionally stable and durable rubber state through chemical cross-linking.

Suction pad

Suction cups are cup-shaped suction cups made of elastomer or plastic that cling elastically to the surface and trap the resulting vacuum. Suction cups create an adhesive connection between the gripper and the workpiece by means of negative pressure.

Grommets

Grommets are ring- or disc-shaped protective inserts that are inserted into openings or edges to allow cables to pass through safely. Grommets protect cables and hoses from sharp edges, seal feed-throughs and can be quickly inserted into holes or gaps.

GRP: Glass fibre reinforced plastic

GRP (glass fibre reinforced plastic) is a robust, lightweight composite material made from glass fibres and a plastic matrix that is used in a wide range of applications in industry, construction and mobility.

CFRP: Carbon fibre reinforced plastic

CFRP (carbon fibre reinforced plastic) is an ultra-light, extremely strong composite material made of carbon fibres and a plastic matrix that is used in highly stressed lightweight construction applications.

CAD modelling

CAD modelling is the digital design of technical components and tools that serves as the basis for production, simulation and prototype development in industry.

Keyboard and switch covers

Keyboard and switch covers are elastic protective components that protect keys and operating elements from dust, moisture and dirt. At the same time, they maintain the operating function by transmitting the actuation feel and enabling reliable sealing.

Shore hardness

The Shore hardness measures how deeply a test pin penetrates a material and thus provides information about its degree of hardness - a decisive factor in the selection of elastic and technical materials.

Profile seal

A profile seal is a seal with a defined cross-sectional shape (round, rectangular, hollow or with a complex profile) that ensures a seal between two components. It is made from elastomers and is used wherever gaps, movements or unevenness need to be compensated for.

Outgassing

Outgassing is the escape of volatile substances from materials and can lead to malfunctions, contamination or optical faults in sensitive applications.

Valve seal

A valve seal is an elastic component that reliably seals the flow of gases or liquids in a valve. The seal prevents leaks, compensates for pressure and temperature changes and ensures that the valve fulfils its switching, control or shut-off function reliably and permanently.

PP: Polypropylene

Polypropylene (PP) is a lightweight, chemical-resistant thermoplastic with a wide range of applications that is ideal for technical plastic parts and rubber-plastic composite solutions.

RTV silicone: Room temperature curing solid silicone

RTV silicone is a room temperature curing silicone rubber that cures without heat or pressure. It is particularly suitable for sealing, bonding, potting and mould making and is less strong and temperature-resistant than HTV and LSR.

Bellows

A bellows is an elastic component with a corrugated, accordion-like geometry that absorbs movements, changes in length or swivelling movements without losing its protective or sealing function. It protects sensitive components such as joints, shafts or guides from dirt and moisture and at the same time enables a flexible, permanently movable connection.

HNBR: Hydrogenated NBR

HNBR is a particularly heat-, oil- and ageing-resistant elastomer that is ideal for durable seals and technical components in dynamically stressed applications.

Shaft seal

A shaft seal is a sealing element that seals between a rotating shaft and a housing. It prevents lubricants from escaping and at the same time protects against dirt, dust and moisture.

HTV silicone: High-temperature curing solid silicone

HTV silicone is a high-temperature curing solid silicone rubber that becomes a permanently elastic material when heated. It combines high mechanical strength with excellent resistance to temperature, ageing and chemicals.

Fatigue

Fatigue refers to the progressive degradation of material due to repeated mechanical stress and is a key factor in the design of durable technical components.

Titanium

Titanium is an extremely corrosion-resistant, lightweight and high-strength material that is used in aviation, medical technology and for rubber-metal composite parts in aggressive environments.

Saturated and unsaturated polymers

Saturated polymers have only single bonds in the main chain and are resistant to ageing, while unsaturated polymers contain double bonds in the main chain and are easier to crosslink; EPDM is a speciality because its double bond is in the side chain.

Polymerisation

Polymerisation is the chemical reaction in which many monomers are combined to form long polymer chains - the basis for plastics and rubber elastomers.

Tool costs

Tool costs are the expenses for the manufacture of tools and have a significant influence on the profitability of series production.

Aluminium

Aluminium is a lightweight, corrosion-resistant material with high thermal conductivity that is used in a variety of ways as a construction material and support element in technical components.

Tensile strength

The tensile strength is the maximum stress that a material can withstand under tensile load and is a key parameter for the mechanical strength of elastomers.

Rubber-Plastic Composite Parts

Rubber-plastic composite parts are hybrid components in which elastic and thermoplastic components are functionally combined - ideal for seals, housings and flexible technical solutions.

Rebound resilience

Rebound resilience describes the ability of a material to return energy after rapid deformation - crucial for dynamic applications such as spring elements or dampers.

Deburring

Deburring is the process of removing burrs from components to ensure the function, appearance and safety of technical products.

Degreasing

Degreasing is an essential cleaning step for removing residues from components to ensure optimum adhesion during vulcanisation, bonding or coating.

Cycle time

The cycle time describes the complete duration of a production run during injection moulding or pressing and is a key parameter for efficiency and output.

Heat resistance

Heat-resistant materials retain their properties at high temperatures and are ideal for industrial and technical applications.

Seals

Seals prevent leaks in pipework, motor and system components. They also compensate for manufacturing tolerances and protect processes against pressure, temperature and media stress.

CR: Chloroprene rubber

Chloroprene rubber (CR) is a versatile, weather- and flame-resistant elastomer that is often used for seals, hoses and technical components for indoor and outdoor use and is also known as neoprene.

LABS (paint wetting impairment substances)

LABS are substances that interfere with the wetting of paints and must therefore be strictly avoided or tested in paint-critical applications.

ISO 13485

ISO 13485 explained: an overview of the requirements, areas of application and benefits of certification for medical technology.

Caoutchouc vs. rubber vs. elastomer

Rubber is the raw material, rubber is the end product created by vulcanisation, and elastomer is the superordinate material class of elastic polymers.

Rubber caps

Rubber caps reliably protect components from dust, moisture and mechanical impact.

Molded Rubber Parts

Moulded rubber parts are elastic components made from vulcanised rubber by pressing, transfer moulding or injection moulding. They are manufactured according to drawings and are used as sealing, damping or functional elements in technical applications.

Rapid tooling

Rapid tooling is the accelerated production of functional tools for the rapid production of prototypes or small series under near-series conditions.

Elasticity

Elasticity is the ability of a material to deform under load and then return completely to its original shape - essential for flexible technical components.

Express Services

Express production refers to the particularly fast production of prototypes, tools or small batches and accelerated development projects with drastically reduced delivery times.

Anti-ageing agent

Anti-ageing agents are functional additives that protect elastomers and plastics from damaging influences such as oxygen, ozone, UV radiation or heat, thereby significantly extending their service life.

Aramid / Kevlar

Aramid / Kevlar is an extremely tensile, lightweight and heat-resistant fibre that is used as reinforcement in rubber composite parts, sealing systems and protective applications.

Housing and cover with integrated seal

Housings and covers with integrated seals are components in which the sealing function is embedded directly in the plastic or metal part. The sealing function is usually realised as an overmoulded or pressed-in rubber sealing lip. They enable reliable sealing without a separate sealing component and are often used for compact, easy-to-install assemblies.

TPE: Thermoplastic elastomers

TPEs are elastic, malleable materials with rubber-like behaviour that can be thermally processed and recycled like plastics - ideal for flexible seals, handles and hybrid parts.

Tempering

Annealing is a thermal post-treatment that reduces residual stresses, stabilises material properties and improves the functionality of technical components.

PU: Polyurethane elastomer

PU elastomers are dimensionally stable, abrasion-resistant plastics with high mechanical strength that are ideal for rollers, seals and shock absorbers in heavy-duty industrial applications.

Assembly Services

Component assembly comprises the assembly of individual components into a functional unit as an assembly.

Elastomer rollers

Rubber rollers transmit forces, dampen vibrations and protect surfaces in printing machines, conveyor systems and packaging lines.

Copolymerisation

Copolymerisation is the simultaneous polymerisation of different monomers to produce polymers with specifically adjustable properties for technical and industrial applications.

SBR: styrene-butadiene rubber

SBR is a cost-effective, abrasion-resistant elastomer with good mechanical properties that is mainly used in tyres, seals and general moulded rubber parts.

IIR: Butyl rubber

Butyl rubber (IIR) is a particularly gas-tight, weather- and chemical-resistant elastomer that is mainly used in tyres, seals and membranes.

Rubber-fabric composite parts

Rubber-fabric composite parts are elastic components with integrated fabric inserts that ensure high tensile strength, dimensional stability and dynamic load-bearing capacity - for example in membranes, seals or conveyor belts.

Freeze deburring

Freeze deburring is a process for removing burrs, particularly on rubber parts, by cooling and mechanical blasting.

Primer

Primers are adhesion-promoting primers that improve the adhesion between rubber, plastic or metal and ensure a permanent bond in composite and coating applications.

Elongation

Elongation refers to the change in length of a material under tensile load and is a key parameter for assessing the elasticity and breaking strength of technical materials.

Adhesion

Adhesion is the physical holding force between two different materials at their interface and is a key factor for strong, durable connections in technology and industry.

Oil resistance

Oil-resistant materials permanently withstand aggressive oils and are used in seals, hoses and technical components.

Tool cleaning

Tool cleaning ensures reliable, clean moulding, protects against burr formation and extends the service life of tools in series production.

Toolmaking

In elastomer production, toolmaking refers to the development and manufacture of high-precision tools that are used in the production of rubber, plastic and composite parts for moulding.

Special alloys

Speciality alloys are highly developed metal mixtures for extreme requirements in technology, medicine and industry - especially where corrosion, temperature or load limits of standard materials are exceeded.

Bearing bolt

A bearing pin is a cylindrical connecting element that serves as a pivot or swivel axis for moving components. It transmits forces, guides movements and secures the position of components within a bearing or a joint connection.

EPDM: Ethylene propylene diene rubber

EPDM is a weather, UV and chemical-resistant elastomer with high thermal stability that is used in particular for durable seals, hoses and outdoor applications in industry and construction.

PPS: Polyphenylene sulphide

Polyphenylene sulphide (PPS) is a high-temperature and chemical-resistant precision plastic that is used in media-exposed and dimensionally critical components, especially in hybrid solutions.

Rubber expansion joints

Rubber expansion joints are flexible connecting elements that compensate for movements, vibrations and pressure surges in pipework. Thanks to their elastic structure, they can absorb changes in length, lateral displacements and angular movements and thus protect connected system components from mechanical stress, vibrations and tension in the pipework system.

Compression moulding

Compression moulding is a process for manufacturing moulded rubber parts in which a rubber compound is compressed under pressure and heat in a closed mould and vulcanised directly.

RoHS

RoHS restricts the use of certain hazardous substances in electrical and electronic equipment in order to reduce environmental and health risks. Products may only be sold in the EU if all components comply with the specified limits for listed hazardous substances.

Compound

A compound is a customised material mixture of polymer and additives that is specifically tailored to the requirements of a particular technical application.

Stainless steel

Stainless steel is a corrosion and temperature-resistant material that is used for durable, hygienic and mechanically resilient components in demanding technical applications.

Residual materials

Residual materials are recyclable material residues from production that can be specifically collected and fed back into the production cycle to conserve resources.

Peroxide crosslinking

Peroxides are reactive cross-linking chemicals that produce stable, temperature- and chemical-resistant elastomer structures without sulphur bridges in rubber processing.

FDA conformity

FDA compliance means that a material or product meets the requirements of the U.S. Food and Drug Administration and is safe for contact with food, drinking water or pharmaceutical applications. Only approved ingredients may be used and the material must not release any substances of concern into the medium.

Transfer moulding

Transfer moulding is a rubber moulding process in which the material is pressed from a heated chamber into a closed mould where it is cross-linked under pressure and temperature - ideal for precise components with inserts.

Fillers

Fillers are functional additives in rubber or plastic compounds that specifically influence mechanical properties, processability or cost structure.

Stress cracking

Stress cracking is the gradual formation of cracks in plastics due to the interaction of stress and chemical media - often with critical consequences for component safety.

Plasticiser

Plasticisers are additives that make rubber and plastics more elastic and easier to process and are mainly used in flexible sealing and moulded parts.

PES: Polyester

Polyester (PES) is a robust, chemical-resistant thermoplastic that is used both as an engineering plastic and as a fabric reinforcement in rubber composite parts.

Vibration dampers

Vibration dampers reduce vibrations and noise in machines and vehicles.

Rubber recycling

Rubber recycling includes mechanical, thermal and chemical processes for the reuse of vulcanised rubber products as raw materials or additives in new applications.

REACH

REACH is an EU regulation for the registration, evaluation and regulation of chemical substances in order to better protect people and the environment. Companies must prove the safety of the raw materials they use and inform customers if their products contain substances of concern.