{"id":1456,"date":"2026-06-04T10:01:27","date_gmt":"2026-06-04T10:01:27","guid":{"rendered":"https:\/\/www.htpweb.net\/?p=1456"},"modified":"2026-06-30T14:47:20","modified_gmt":"2026-06-30T14:47:20","slug":"double-seal-overmoulding-on-aluminium-when-the-solution-seemed-impossible","status":"publish","type":"post","link":"https:\/\/www.htpweb.net\/en\/2026\/06\/04\/double-seal-overmoulding-on-aluminium-when-the-solution-seemed-impossible\/","title":{"rendered":"Double-seal overmoulding on aluminium: when the solution seemed impossible"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\"><em>How we developed a seal<\/em><em>&nbsp;<\/em><em>in 4 weeks that others had failed to produce in three years<\/em><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong><em><strong><em>When they called us, the project was nearly dead.<\/em><\/strong><\/em><\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Three years of attempts, different suppliers, resources invested. And the problem was still there, unsolved. They were seriously considering giving up on&nbsp;the entire project.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">We sat down with their technical team and listened. Not just to the stated problem \u2014 but to everything: the actual&nbsp;operating conditions, the system constraints, what they had already tried and why it had not worked.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>The problem<\/strong><strong><\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The component was a&nbsp;machined&nbsp;die-cast aluminium valve&nbsp;with&nbsp;very tight tolerances&nbsp;and&nbsp;a stainless steel pin integrated into the upper section. The requirement was to overmould two sealing gaskets&nbsp;simultaneously \u2014 one at each end of the valve, 180 degrees apart.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">But that was not all. During the discussion, a critical requirement emerged that further complicated matters: the compound had to ensure&nbsp;low friction under operating conditions. The part operates&nbsp;in a system where actuation force must be minimal \u2014 yet the seal must be reliable and consistent over time.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Two requirements pulling in opposite directions. And which explains, at least in part, why others had failed.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Why aluminium is a <\/strong><strong>challenging<\/strong><strong>&nbsp;substrate<\/strong><strong><\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">In our&nbsp;line of &nbsp;work, we know this&nbsp;all too&nbsp;well: aluminium is one of the most complex substrates to work with. It is not like steel. Its surface oxidises naturally, with chemical properties&nbsp;that vary&nbsp;depending on the alloy, the surface treatment, and even the storage conditions of the component.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Achieving a durable structural bond between rubber and aluminium requires: specific and controlled surface preparation, primers and bonding agents compatible with that specificalloy and the selected compound, process parameters optimised to the last&nbsp;detail;&nbsp;and a mould designed to manage the flow of the compound&nbsp;on both sides simultaneously.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong><em><strong><em>There are no shortcuts. Every variable matters.<\/em><\/strong><\/em><\/strong><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Three years of failed attempts<\/strong><strong><\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The customer \u2014 a&nbsp;multinational industrial group \u2014 had already faced the problem head on. For almost&nbsp;three years, various suppliers had attempted to develop a solution. These were large companies, with in-house&nbsp;resources and laboratories. The result was always the same: an inability to guarantee stable, long-lasting adhesion, or sealing issues under real operating conditions.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The project was on the verge of being abandoned.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>What we did<\/strong><strong><\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">We worked on three fronts simultaneously: selecting and optimising the compound to meet the required tribological characteristics, developing a surface treatment process specifically tailored to that aluminium alloy, and designing the mould for the simultaneous overmoulding of the two gaskets at 180 degrees, with the stainless steel pin as the central element to be managed.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong><em><strong><em>It was not straightforward. <\/em><\/strong><\/em><\/strong><strong><em><strong><em>But it is exactly the sort of problem we are used to dealing with.<\/em><\/strong><\/em><\/strong><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>The result<\/strong><strong><\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Four weeks after our&nbsp;first meeting, we delivered the samples in the smallest size.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">I will never forget the technical team\u2019s reaction.&nbsp;After three years of failed attempts, they did not expect to see those samples so soon. And above all, they did not expect them to work.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong><em><strong><em>They worked.<\/em><\/strong><\/em><\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">We currently manufacture four sizes of that component using 4-cavity and 8-cavity moulds. We have been in production for over four years, maintaining consistent quality and with no issues encountered in the field.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>If you<\/strong><strong>&nbsp;a<\/strong><strong>re facing a similar problem<\/strong><strong><\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Overmoulding on aluminium&nbsp;is not impossible. It is complex, requires specific expertise in materials, surface treatments and process, and leaves no room for approximation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">If you have a sealing challenge that others have not been able&nbsp;to solve \u2014 on aluminium, special alloys, engineering plastics, or stainless steel \u2014 get in touch. The first thing we do is listen.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Foresti Alexander<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<div class=\"wp-block-group\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<p class=\"wp-block-paragraph\"><strong>Contact us: <\/strong>info@htpweb.net &nbsp;| &nbsp;www.htpweb.net &nbsp;| &nbsp;+39 030 7401853<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">HTP \u2013 High Tech Project S.r.l. &nbsp;| &nbsp;Via Lanfranchi 15, Palazzolo S\/O (BS) Italy &nbsp;| &nbsp;Sealing Technology since 1980<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n<\/div><\/div>\n","protected":false},"excerpt":{"rendered":"<p>How we developed a seal&nbsp;in 4 weeks that others had failed to produce in three years When they called us, the project was nearly dead&#8230;.<\/p>\n","protected":false},"author":2,"featured_media":1466,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[19],"tags":[],"class_list":["post-1456","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-from-htp"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.9 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Double-seal overmoulding on aluminium: when the solution seemed impossible - HTP - High Tech Project<\/title>\n<meta name=\"description\" content=\"Double-sealed overmoulding on aluminium: how HTP solved a sealing problem in four weeks that major suppliers had been unable to resolve for three years. 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