Sponge & Foam Gasket Material

We manufacture sponge gaskets and foam gaskets that range from soft to firm in density and have different physical properties for resistance to chemicals and temperatures. Foam gaskets are flexible with an open cell structure and are used for thermal and acoustic insulation, shock and vibration control, and to seal out dust and moisture.

Sponge gaskets and materials have a closed cell structure and are soft, compressible, and perform well in extreme temperatures. They effectively seal out fluids and are commonly used in outdoor applications and for vibration reduction.

Differences in the Physical Properties of Sponge Gaskets and Foam Gaskets

Sponge and foam gaskets may appear similar and manufactured using similar processes, but they have different mechanical and physical properties.

The specific properties of foam gaskets vary depending on the type of polymer used. Cross-linked polyethylene foam provides excellent chemical resistance, plus good mechanical and thermal insulation. Polyurethane foam gaskets are used for cushioning and ideal for thermal and acoustic insulation, and dust and moisture sealing. Both compounds perform well in wet environments.

Sponge gasket material is made using a similar method, but the cells produced are more self-contained and evenly distributed. This closed cell structure provides better compression set resistance and compression recovery and completely blocks the passage of gas or fluid. Materials such as neoprene and silicone deliver superior temperature resistance and many neoprene sponge gaskets also meet UL flame ratings. These properties make sponge gaskets and materials an excellent option for automotive, construction, marine and HVAC applications.

Custom Gaskets Manufactured in a Range of Sponge and Foam Materials

Accurate Felt & Gasket (AFG) manufactures custom gaskets using a variety of sponge and foam materials. As an authorized distributor of gasket materials, we stock a large and varied inventory of open cell and closed cell foam, sponge, rubber and more — in different thicknesses, hardness, and densities to meet your requirements.

Foam and sponge gasket materials are available in varying densities and polymers that make them suitable for diverse applications as gaskets, seals, spacers, bumpers, and tape. The material options below will help you determine what’s best for your application.  We also offer die cutting, laminating, and other services to give you gaskets that match your unique requirements.

Contact us for assistance in selecting the right material for your needs, or request a quote if you've already decided which material is right for you.

Sponge Gasket Materials

Accurate Felt & Gasket offers several materials providing a wide operating temperature range and UV or flame resistance. Some of the common materials used for sponge gaskets include:

Closed Cell Neoprene/PVC/Nitrile sponge rubber is an economical sealing and gasket material for applications that require good resistance to chemicals and conformance with UL 94 flammability ratings. This material blend exhibits the best properties from each individual elastomer and performs well in temperatures from -40°F to 200°F (-40°C to 93°C). Closed cell neoprene/PVC/nitrile rubber is one of many materials available at Accurate Felt & Gasket for custom and die-cut seals and gaskets.

Closed Cell Neoprene offers good resistance to acid, alkali, gasoline, and oil. Closed cell neoprene is excellent for applications that require resistance to UV, oxidation, and ozone in long-term outdoor applications. This series of closed cell neoprene is a 100% neoprene rubber with a temperature range of -40°F to 150°F (-40°C to 66°C). Neoprene sponge gaskets are available in soft (SCE41NEO), medium (SCE42NEO) and firm (SCE43NEO) durometers.

EPDM (Ethylene Propylene Diene Monomer) Closed Cell sponge rubber exhibits very good aging properties and compressibility, and offers excellent resistance to ozone and oxidation, making it useful in a variety of industrial and commercial applications. Accurate Felt & Gasket custom die-cuts parts in EPDM elastomers for customers that span across industry groups and international locations. Our closed cell EPDM sponge is available in different densities, and each offers a unique set of physical properties.

Closed Cell Nitrile (Buna-N) is an excellent gasket material for sealing applications that require fuel, oil, and UV resistance. Closed cell nitrile exhibits high resistance to vegetable oil, animal oil, and mineral oil. It also performs well as a gasket or sealing material in petroleum-based applications. This series of closed cell nitrile is a 100% Nitrile rubber with a temperature range of -40°F to 250°F (-40°C to 121°C). It is available in soft (41), medium (42) and firm (43R) densities. 

Closed Cell Silicone offers excellent sealing qualities, plus compression set, flame, ozone, and UV resistance. This high-end closed cell silicone is widely used for demanding applications and is excellent for applications that encounter extreme temperatures between -103°F and 450°F (-75°C to 232°C). Silicone closed cell sponge is available in soft, medium, firm, and extra firm densities. Silicone sponge gaskets are also available in low compression set, flame retardant, and fiberglass reinforced grades. 

Closed Cell Epichlorohydrin (ECH) offers excellent fuel and chemical resistance and performs well in applications where temperature can range from -40°F to 300°F (-40°C to 149°C). ECH is available in soft, medium soft, medium, and extra firm densities.

Closed Cell Ethylene Vinyl Acetate (EVA) is light weight and odorless. Closed cell EVA foam exhibits good mechanical strength, excellent chemical resistance, high buoyancy, low water absorption, and good acoustic properties. Closed cell EVA foam demonstrates excellent climate, temperature, and aging resistance in outdoor applications. It is available in in 2# and 4# densities.

Closed Cell Neoprene/EPDM/SBR combines the best qualities of its three polymers, creating an excellent gasket material that is used in many diverse indoor and outdoor applications. Neoprene/EPDM/SBR closed cell sponge is resistant to ozone, sunlight, and oxidation. This material meets UL157, UL50E, UL50, UL48, UL508 and UL94HF-1, and is available in soft (SCE41B), medium soft (SCE42B), medium (SCE43B) and extra firm (SCE45B) densities. Neoprene blend sponge gaskets perform well in applications that range in temperature from -40°F to 200°F (-40°C to 93°C). 

Closed Cell PVC/Nitrile sponge combines excellent energy, impact, and shock absorbing properties, and good chemical resistance. Closed cell PVC/nitrile sponge is available in five grades MLC (4 pcf), MLC-2 (4 pcf), AHC (7 pcf), SCC (12 pcf), and SSC (12 pcf). Depending on the grade, our PVC/nitrile closed cell sponge meets ASTM D 1056-68, 1056-85, 91, 98, 07, ASTM-D-6576-07 Type 2 Grade A & B Condition soft, UL 94 HF-1, UL 94 HBF, UL 94 V0, and FMVSS-302 standards. Closed cell PVC/nitrile sponge is designed for applications where temperatures can range between -40°F to 200°F (-40°C to 93°C). 

Closed Cell Neoprene/PVC/Nitrile sponge is an economical sealing and gasket material for applications requiring good resistance to chemicals and conformance with UL 94 flammability ratings. Closed cell neoprene/PVC/nitrile sponge meets ASTM-D-1056-68, ASTM-D-1056-85, 91, 98, 07 2C1, 2B2 and 2B3, ASTM-D-6576-07 TYPE 2, Grade A & B condition soft and medium standards. It is an excellent gasket material for automotive applications and electrical enclosures that require a UL 94 HF-1, UL 94 V0 or UL 94 HBF flammability rating. Neoprene/PVC/nitrile closed cell sponge is available in three densities: IV1 (4 pcf), IV2 (6 pcf), and IV3 (8 pcf). This material works well in temperatures ranging from -40°F to 200°F (-40°C to 93°C). 

Foam Gasket Materials

Accurate Felt & Gasket offers closed cell and open cell foam gasket materials that are diverse in their chemical composition and mechanical properties. Common foam types used for gaskets and other die cut parts include:

Cross-Linked Polyethylene Foam (Volara®) has good thermal insulating properties and excellent chemical properties that make it suitable for a wide range of applications. Cross-linked polyethylene foam has a smooth skinned surface on both sides and is supplied in continuous rolls. Cross-linked polyethylene foam is available in six different grades: styles 2A and 2AF (UL rated and meets ASTM E84-03 Flame spread index 5) are 2# density; style 4A and 4EO are 4# density; 6A and 6EO are 6# density.

Open Cell Polyurethane Foam is available in 2#, 4#, and 6# densities in both polyether- and polyester-based formulations. Open cell polyurethane foam can be found in a variety of applications and industries like acoustical, appliance, automotive, filtration, industrial, gaskets, marine, military, tapes, dust seals, and speaker surrounds. Standard grades of open cell polyurethane foam meet both the UL 94 HF1 and FMVSS-302 flammability ratings.

Micro Cellular Urethane Open Cell Foam (PORON®) is found in diverse industrial and commercial applications. Our skinned micro cellular urethane foam options include medium- to firm-density urethane foams that are engineered in several formulations. All are characterized by high resiliency and rebound within a broad temperature range and meet FMVSS-302. These materials offer excellent compression set resistance and are lightweight. Well suited for electrical panel door seals, these materials are cast to the finished thickness and meet UL50, UL508, UL94, and UL514B standards.

PVC Foam is general-purpose, closed cell foam with good air, moisture, and dust sealing properties, plus UV and chemical resistance. Density range of 6 to 15 PCF.

Request a Quote for Custom Sponge and Foam Gaskets

Accurate Felt & Gasket also offer a variety of sponge and foam materials that exhibit good dielectric properties and can be used for electrical/electronic applications. Request a quote on open cell and closed cell sponge or foam materials, or custom gaskets made from these materials. Or, contact us to learn more about our vast offering of gasket materials for any sealing application.