Understanding formed-in-place gasketing and its benefits

Formed-in-place gaskets (FIPG), also known as foam sealing or foam gasketing, are a critical solution for achieving high-performance sealing across a wide range of industries. FIPG is the process of applying a liquid gasket material directly onto a part, where it then cures to form a durable, highly conforming seal. This liquid foam material flows into grooves or onto flat surfaces, bonding directly to the substrate and adapting to complex geometries, surface imperfections, or variable part designs.

Once applied, the material expands into a foam and hardens - either through air curing, heat, or a chemical reaction - forming a resilient, custom-fit gasket. This method is ideal for applications requiring exact sealing performance, especially in automotive, electronics, HVAC and appliance manufacturing.

Why use FIPG over traditional gaskets?

Traditional gaskets often come pre-cut, which limits flexibility in design and can lead to sealing issues when dealing with irregular surfaces or tight tolerances. FIPG offers a fully customised seal, applied robotically or manually, ensuring better performance and consistency. Key benefits of formed-in-place foam gasketing (FIPG) include:

Superior Surface Adaptability: Fills surface scratches, grooves, and imperfections for a reliable seal.

Custom Application: Applied precisely where needed, even on complex or 3D geometries.

Strong Adhesion: Bonds directly to the part, creating a secure and durable connection.

Flexible Material Control: Adjust foam width, height, and density during application.

Manual versus robotic FIPG application

For small-scale or less demanding projects, FIPG can be applied manually using foam cartridges or handheld applicators. This offers a couple of advantages, including cost-effective for prototypes or home use, and easy of deployment with minimal setup.

But there are a number of limitations, too. Results are operator-dependent, and there is less repeatability and precision. Further, it is only suitable for low to mid IP ratings.

So what about robotic application? Robafoam specialises in robotic FIPG application using a single-component foam system. This method offers unmatched precision and performance.

Consistent Quality: Repeatable seals with tolerances as low as 0.1mm

Top IP Ratings: Ideal for applications needing high ingress protection

Scalability: Perfect for high-volume production with minimal waste

Enhanced Functional Performance: Supports NVH (noise, vibration, harshness) reduction, bonding, and cushioning.

FIPG is used across numerous sectors that demand reliable and high-performance sealing. Common applications include: automotive electronics and lighting; HVAC components; appliance seals; electrical enclosures; and industrial equipment.

With customisation built into the process, FIPG allows manufacturers to meet strict regulatory, safety, and performance standards without compromising design flexibility.

Robafoam has perfected the art of liquid foam sealing using its proprietary technology. Whether you need prototype support or a fully automated production line, Robafoam's FIPG systems are designed to deliver reliability, repeatability, and performance.

If you're still using traditional gaskets or struggling with inconsistent seals, now's the time to explore FIPG solutions.