Protective housing

What are protective housings?

A protective housing is a protective enclosure or panelling that protects sensitive components from damaging environmental influences. It fulfils the dual task of protecting the interior and at the same time protecting the surroundings from potential internal hazards such as electricity, heat or moving parts. The design of a protective housing depends heavily on the application, but usually follows a standardised principle:

Support structure or housing body: forms the mechanical frame
Sealing systemprevents the ingress of liquids, dust or gases
Locking and mounting elements: allow access for maintenance or replacement

Protective enclosures can be stationary or mobile, with a transparent cover, ventilation or EMC shielding for electromagnetic compatibility. In industry, they come in a wide range of sizes - from enclosures for microswitches to control cabinets. The protective effect of an enclosure is defined by IP protection classes. These indicate the extent to which an enclosure is protected against foreign bodies and water. For example, IP67 characterises a completely dust-tight enclosure that can withstand temporary immersion in water. Soft-sealing elastomer elements play a particularly important role in sealing against liquid or gaseous media.

Functions & applications of protective housings

The core function of a protective housing is to protect components or assemblies from external influences and to create a safe operating environment. In addition, protective enclosures fulfil numerous

Additional functions that vary depending on the area of application: Mechanical protection: against shocks, vibrations and oscillations
Environmental protection: Sealing against dust, moisture, chemicals or UV radiation
Electrical insulation: protects the user from live parts
Temperature management: dissipation or insulation of heat.
EMC shielding: protection against electromagnetic interference
Hygiene protection: smooth, cleanable surfaces in sensitive areas

Typical applications:

Electrical engineering and electronics: housings for control units, sensors, switches or circuit boards
Mechanical and plant engineering: protection of control systems, drives or hydraulic components
Automotive industry: Covers and sensor housings with integrated seal
Medical and laboratory technology: hermetically sealed Housing For appliances with high hygiene standards
Outdoor and building technology: weatherproof housings for surveillance cameras, lights or measuring devices
Chemical industry: corrosion-resistant housings for Valves, pumps or control units

Protective housings make a decisive contribution to the longevity and functional reliability of technical systems. They prevent malfunctions caused by environmental influences and ensure that devices work reliably even under harsh conditions.

Components and materials of protective housings

The choice of material for a protective housing depends on the mechanical load, ambient temperature, chemical resistance and electrical requirements. In addition to metal and plastic enclosures, hybrid solutions with integrated elastomer seals are also used, which offer a high level of protection with simple installation.

Metals:

Stainless steelhigh corrosion resistance, hygienic, well suited for food and chemical plants
AluminiumLightweight, conductive, good heat dissipation, often used for electronic housings
Sheet steel: robust, economical, often powder-coated for corrosion protection

Plastics:

Polycarbonate (PC): impact-resistant, transparent, UV-resistant
ABSeconomical and dimensionally stable, for indoor applications
Polyamide (PA): tough and temperature-resistant
PVC: chemically resistant, suitable for damp or aggressive environments

Elastomers / rubber components for sealing solutions:

EPDMWeather and ozone resistant, for outdoor seals
NBRoil-resistant, for technical housings with hydraulic connection
Silicone (VMQ): resistant to high temperatures, for medical and sterile environments

To ensure that protective enclosures fulfil their full function over long periods of time, they have a number of design features that determine both the degree of protection and ease of installation:

Integrated Seals or circulating Sealing lips to guarantee the IP protection class
Pressure equalisation elements for changing ambient temperatures
Cable glands with elastomer seal
Mounting systems for attachment to rails, walls or devices

Protective housings are usually Injection Molding (for plastic), sheet metal forming and welding or CNC milling (for metal). Elastomer seals are then clamped, injected or moulded in. vulcanised, to achieve a permanent seal.

Further entries

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.

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.

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.

LSR: Liquid silicone

LSR is a liquid silicone rubber produced on a VMQ or FVMQ basis and processed by injection moulding. The material combines high elasticity, purity and temperature resistance.

Assembly Services

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

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.

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.

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.

ISO 13485

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

Biocompatibility

The proof of biocompatibility proves through standardised tests that a medical device or material does not cause any harmful reactions in the human body.

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.

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.

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.

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.

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.

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.

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.

Rubber blank

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

Metal oxide crosslinking

Metal oxide crosslinking is a crosslinking process that is mainly used for chloroprene rubber and produces particularly durable, ageing and flame-resistant rubber parts.

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.

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.

Inserts

Inserts are solid components that are embedded in rubber components during processing in order to specifically extend their functionality, stability or fastening options.

PA: Polyamide

Polyamide (PA) is a robust, wear-resistant plastic with very good strength and chemical resistance, which is used in particular in technical components and rubber-plastic composite systems.

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.

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.

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.

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.

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.

Tool costs

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

Compound

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

Synthetic rubber

Synthetic rubber is an industrially manufactured elastomer material that is categorised into main chemical groups and whose properties can be specifically adapted to technical requirements.

Series production

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

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.

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.

Deburring

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

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.

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.

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.

Sealed seats

Sealing seats are machined contact surfaces that accommodate seals in a form-fit and force-fit manner, thus ensuring permanent media separation protection.

Prototype construction

Prototyping is the targeted production of functional sample parts for early testing and optimisation of geometry, material behaviour and processability before the start of series production.

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.

Tempering

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

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.

Fillers

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

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.

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.

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.

Freeze deburring

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

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.

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.

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.

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.

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.

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.

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.

Tool cleaning

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

Mould cavity / cavity

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

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.

Peroxide crosslinking

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

Polymerisation

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

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.

Glass transition temperature

The glass transition temperature (Tg) is the temperature range in which a polymer changes from elastic to glassy and largely determines its low-temperature flexibility.

EN 9100

EN 9100 explained: an overview of the requirements, areas of application and benefits of certification for the aviation, aerospace and defence industries.

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.

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.

Sampling

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

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.

Elongation at break

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

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.

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.

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.

Adhesion promoter

Adhesion promoters are chemical bonding agents that permanently bond rubber with other materials and thus form the basis for resilient rubber composite parts.

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.

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.

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.

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.

Ageing

Ageing describes the gradual change in material properties due to external influences such as heat, UV radiation or media, which can lead to long-term impairment of function and service life.

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.

Crosslinking chemicals

Cross-linking chemicals ensure the permanent elasticity and dimensional stability of rubber through chemical reaction - a key component in the production of functional rubber parts.

Silane crosslinking

Silane crosslinking is a moisture-controlled crosslinking process for plastics and elastomers that enables mechanical stability at moderate processing temperatures.

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.

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.

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.

NR: Natural rubber

Natural rubber (NR) is a highly elastic, tear-resistant elastomer made from renewable raw materials that is primarily used in dynamically stressed components such as tyres, dampers and conveyor belts.

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.

Rapid tooling

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

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.

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.

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.

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.

Vibration dampers

Vibration dampers reduce vibrations and noise in machines and vehicles.

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.

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.

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.

Rubber

Rubber is an elastic material of natural or synthetic origin that is vulcanised into durable components for sealing, damping and technical applications.

Heat resistance

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

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.

Rubber-Metal Composite Parts

Rubber-metal composite parts are mechanically stable components in which elastomer and metal are inseparably combined - ideal for bearings, dampers and technical sealing systems.

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.

Protective housing

A protective housing encapsulates sensitive components and prevents damage caused by dirt, water or impact.

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.

Elastomer rollers

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

Sulphur crosslinking

Sulphur crosslinking is a proven vulcanisation process in which rubber is crosslinked with the aid of sulphur to form an elastic, dimensionally stable and mechanically resilient material.

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.

Rubber caps

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

ISO 14001

ISO 14001 explained: an overview of the requirements, areas of application and benefits of the international standard for environmental management systems.

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.

Copolymerisation

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

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.

Valves

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

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.

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.

Oil resistance

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

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.

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.

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.

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.

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.

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.

FKM: Fluororubber

FKM is a heat- and chemical-resistant high-performance elastomer for seals and components in extremely demanding industrial applications.

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.

Degreasing

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

FVMQ: Fluorosilicone

FVMQ is a cold-flexible, fuel- and weather-resistant fluorosilicone elastomer that is primarily used in the aviation and automotive industries for demanding sealing applications.

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.

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.

Outgassing

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

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.

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.

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.

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.

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.

PC: Polycarbonate

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