For rubber components that operate in extreme environments, material selection is critical. High temperatures, aggressive chemicals, pressure fluctuations, UV exposure, and outdoor weathering can all cause premature failure if you specify the wrong elastomer.
Whether you’re designing extruded rubber seals, custom gaskets, vibration isolators, or custom molded components, choosing the right compound upfront can significantly improve performance, reliability, and service life.
This guide from The Rubber Group is designed to help engineers and buyers select the best rubber material for harsh operating conditions. Keep reading to learn more and contact us to discuss your application.
1. Define Your Environmental Stressors First
Before evaluating specific materials for extreme environments, clearly define what “extreme” means for your application.
Ask yourself these questions.
- What are the continuous and peak operating temperatures?
- Will the part be exposed to oils, fuels, solvents, or chemicals?
- Is there UV, ozone, or outdoor weather exposure?
- Does the component experience pressure, vacuum, or vibration?
- Is the environment static or dynamic (with movement or abrasion)?
By accurately identifying these conditions, you can improve material selection and avoid over-engineering rubber components or risking costly failures.
2. High-Temperature Environments: What Works and What Doesn’t
Not all elastomers perform the same under sustained heat.
Top high-temperature rubber options:
- Silicone (VMQ): Resists high heat, remains flexible at low temperatures, and is ideal for wide temperature ranges
- Fluoroelastomers (FKM): Provide outstanding high-heat performance when there’s chemical exposure. Ultra-low temperature FKM is also available.
- EPDM: Performs well in hot water and steam applications
Materials to avoid: Natural rubber and standard nitrile compounds degrade quickly under sustained high temperatures.
3. Chemical Exposure: Match the Compound to the Media
Chemical incompatibility is one of the most common causes of rubber failure, and it’s especially important to avoid in extreme environments.
General compatibility guidelines:
- FKM (Viton®): Excellent resistance to fuels, oils, and many chemicals
- EPDM: Strong resistance to water, steam, and many acids, but poor performance with petroleum oils
- Nitrile (NBR): Good for oils and fuels, but limited overall chemical resistance
- PTFE-filled or specialty compounds: Used for aggressive chemical environments
Important: Always verify a compound’s compatibility with your specific chemicals and concentrations. Don’t just rely on general categories such as “fuels” or “acids”.
This Chemical Compatibility Chart from The Rubber Group covers hundreds of chemicals and concentrations.
4. Outdoor, UV, and Ozone Exposure
For parts exposed to sunlight and weathering, ozone and UV resistance are essential.
Best choices for outdoor use:
- EPDM: Exceptional ozone and weather resistance
- Silicone: Good UV stability and temperature flexibility
- Neoprene: Balanced weather resistance with mechanical strength
These rubber materials are commonly used in power generation, transportation, and outdoor enclosures for a variety of markets.
5. Compression Set and Long-Term Sealing Performance
In sealing applications, a rubber compound’s ability to maintain its shape over time is just as important as its temperature resistance or chemical compatibility.
Here’s what to consider.
- Low compression set materials are ideal for static seals
- High compression set leads to leakage and frequent replacement
Note: Silicone and FKM compounds are often preferred where long-term sealing reliability is required.
6. Balance Hardness and Mechanical Properties in Extreme Environments
Rubber compounds for extreme environments often require the right balance between:
- Hardness (durometer)
- Tear resistance
- Abrasion resistance
- Flexibility
Examples: Vibration isolation mounts may need a softer rubber compound. Abrasive environments require higher tear strength.
7. Work with a Manufacturer Early in the Design Process
One of the most effective ways to avoid material issues is by involving your manufacturing partner early in your development process.
An experienced supplier can:
- Recommend alternative compounds to reduce costs
- Modify formulations for better performance
- Validate designs with real-world testing
- Ensure manufacturability at scale
Ready to Select the Right Rubber Compound for Extreme Environments?
Selecting the right rubber compound for extreme environments isn’t about choosing the “strongest” material. It’s about choosing the right balance of properties for your specific application.
By applying what you’ve learned in this guide, you can improve reliability and reduce downtime. It’s especially important to pick right manufacturing partner for rubber parts like seals, gaskets, vibration isolators, or custom molded components
Are you designing rubber components for extreme environments? At The Rubber Group, our engineering team can help you choose the right compound, optimize performance, and avoid costly failures.
Contact us to discuss your application and get expert material guidance.