cascade gasket & Mnfg. co.

As part of our full range of services, Cascade Gasket provides rubber and elastomer certified testing services for rubber and elastomer products for the aerospace, bus, communication, maritime, and train industries. We offer physical, thermal, and chemical testing services, including hardness, tensile strength, elongation, adhesion, modulus, and compression set testing. In addition, we can test for tear resistance and abrasion resistance, resilience, and flexibility. Our success in developing superb testing and production practices has earned us AS-9100 and AS-9102 aerospace certifications, as well as ISO 9001:2008 certification. We can also assist with consulting, design, research and development, and prototyping needs in concurrence with, or in addition to our testing services. Contact Cascade Gasket with any product drawings or information to begin the testing process.

Cascade Gasket assisted in the design and then manufactured this flight critical exit door seal for a commercial aircraft. The seal effectively blocks both air and water from the aircraft’s interior, in flight and while grounded, and is composed of three materials: BMS 1-57 silicone rubber, D2000 inter-weave fabric, and inconel metal inserts at the top of the seal. Although rubber compression molding was the primary manufacturing process, several steps were involved in creating the door seal. First, the inconel metal inserts were pre-fabricated and coated, in preparation for receiving the rubber and fabric. Next, the part was hand formed and laid in the mold in four separate sections, blending together only at areas indicated by the print design. The mold was then placed under extreme heat and pressure for 4 hours, allowing the rubber to flow and fill the mold, assuming the shape of the final component, with a final tolerance of +- 0- .030”. After the molding was complete, the part was cleaned and placed in an oven for 3 hours at 350 degrees Fahrenheit, to set the shape and cure the rubber. The final process involved the addition of a secondary seal, applied on the header section of the seal, for extended sealing and management of the product. The final exit door seal is both air and water tight, and measures 48” long by 27” wide.

This featured compression molded rubber seal was made using a grey rubber (BMS 1-57) compound and a corolon fabric. Because the fabric has a denser weave, it serves to increase durability. The rubber and corolon were first hand formed in the mold, then placed in the press at 230 degrees Fahrenheit (F) for 10 to 15 minutes to assume the proper shape and continuity. After the newly formed seal was removed from the mold and cleaned, it was set to post cure at 300 degrees F. During curing, the foam inserts and end plug (BMS 1-68) were formed by curing the liquid into pre-designed molds, and applying pressure and low-heat until complete. After curing, the seal’s holes and overall length were cut, and then it was assembled with the foam inserts and end plug, which serve to increase the product’s lifespan, fit, and performance. The completed seal assembly was designed to be applied in several places on a commercial aircraft, where it was mounted to metal bulkheads, to enable the sealing of metal parts.

Using our manufacturing expertise, Cascade Gasket is able to offer customers rubber gasket and seal design and support services in addition to our precise production processes. We provide all levels of service: research and development, consulting, and design assistance, as well as prototyping. Our engineering disciplines cover manufacturability engineering and material application assessment, and we provide full material selection, stamping, and forming services for end products: gaskets, seals, and modules as well as OEM components and more. Our clients come from transportation industries like aerospace, bus, and train, as well as maritime and communications applications. Our full range of services also includes reverse engineering, concept development, logistics, computer aided engineering (CAE), computer aided manufacturing (CAM), concurrent engineering, and technical support. Cascade Gasket is equipped to assist in all process steps, so contact us with your project information.

This compression molded insulation flange seal is manufactured in a series of steps. First, a foam insert (BMS 1-68) , molded in 2 parts, is bonded together into the designated shape. Next, fabric (D2000) is blended with a red silicone compound (BMS 1-74) using a red iron oxide ingredient which renders the component heat-retardant. The silicone and fabric combination is then hand applied around the foam insert to achieve the proper level of thickness, and then placed in a cool mold. A total of 6 different rubber coated fiberglass inserts are applied to the seal, at specified locations, to create the reinforced attachment points for the seal. The mold is then placed in the press at 320 degrees Fahrenheit (F) for 30 minutes, removed, cooled, and cleaned. The final component shape is set by post curing the seal at 400 degrees F. The completed insulation flange seal is used extensively in engine areas of a commercial aircraft.

Working with both metal and non-metal materials, Cascade Gasket offers full 5-axis waterjet cutting services. The full 5-axis capability combined with a 5 ft. x 10 ft. x 6 in. work envelope allow us to waterjet cut a wide range of pieces for clients in the medical, semiconductor, military, automotive, aerospace, and building industries. Our machines feature 55, 000 psi cutting power from either water only or water and abrasive material jets, and feature a high definition cutting head with near zero kerf compensation software. Edge quality is rated at 4.5 (on a scale of 1 to 5), and we can manufacture to +- 0.005” tolerances. Among the metal materials we work with are aluminum, brass, stainless steel, tungsten carbide, Monel, Inconel, and titanium. We also work with non-metals such as foam, rubber, concrete, glass, wood, plastic, and plexiglass, among many others. We are black belt certified in Six Sigma practices, and operate under lean manufacturing efficiency as well. Contact Cascade Gasket for more information on our capabilities for your products.

Designed for use on commercial airplanes, these featured clamp blocks were value engineered to reduce significant weight of the aircraft. Made from a variety of components, including titanium screws, locking and standard washers, EPDM rubber (BMS 1-50), and carbon fiber composite channels and spacer tubes, the EPDM rubber was molded and cleaned before assembly. Each of the screws, washers, channels, and spacer tubes were purchased to adhere to strict customer specifications, and then assembled with the EPDM rubber block. As a result of the unique combination of rubber, screws, washers, channels, and spacer tubes, the clamp block assemblies were appropriate for use in almost any aircraft application, including hydraulic immersed and fuel pod locations. In addition to reducing the weight of the aircraft, the design of the assemblies reduced FOD and increased the speed and efficiency of installation.

Offering rubber compression and injection molding services, Cascade Gasket specializes in Boeing Aerospace Certified Rubber Compression molding. We mold pieces from small parts to large components, enabling us to compress mold parts up to 144” long and 48” wide at 100 psi. Additionally, we can use compression molds with up to 100 cavities to manufacture our custom gaskets and other parts. Besides organic rubber (from 15 to 80 durometer), we also work with silicone compounds as well as polypropylene, polystyrene, and polyurethane. Cascade Gasket is ISO 9001:2008, AS-9100, and AS-9102 certified. Our injection molding capacity runs from one to thirty cavities, with molds up to 17.25” between bars by 11” and a 1000 cc shot size. Tolerance for all molding processes is to +- 0.005”. Our facility also offers product development and mold making services, with rapid prototyping available. Lead times are quoted on a job by job basis, with emergency and rush service available. We are pleased to serve, in addition to aerospace companies, the train, bus, maritime and communication industries.

Cascade Gasket’s compression molding capabilities include the capacity for custom molded foam and sponges. We work with materials including BMS-168.1, BMS-123, and BMS-160, with color matching finishing capabilities to suit any end application. Our silicone foam and sponges can be manufactured for extreme environment compatibility, making them perfect for aerospace and high temperature applications. Silicone foam and sponges can be compression molded in sizes up to 144”in length at 100 psi, with a +- 0.005” manufacturing tolerance. We offer emergency and rush services, with molds up to 100 cavities to efficiently meet lead time requirements. With AS-9100 and AS-9102 aerospace certifications as well as ISO 9001:2008 certification, our customers can be assured of the quality and integrity of all of our manufacturing processes. For more information, please contact Cascade Gasket today.

For gasket fabrication and cutting services, Cascade Gasket offers a wide capacity range to meet your needs. We specialize in non-metal sheet stock cutting, able to work with pliable gasket material like urethane, neoprene, textiles, silicone, and sponge rubber, as well as other non-metals like chipboard medium density fiberboard (MDF), and cork. We offer die cutting up to 24” in width or diameter and 70” in length, using rotary, punch press, digital, flat bed, or thermal die cutting, and we have an overall cutting capacity of 5’ by 10’ to a +- 0.001” tolerance. We can fabricate and cut gaskets to your prints in any file format, including AutoCAD (.dwg and .dwz extensions), SolidWorks, Unigraphics, and any common image file. Just a few additional materials we work with include foil, plastic, vinyl, and adhesive backed materials. Our facility engineers are black belt certified in Six Sigma, and we operate to lean manufacturing efficiency. Contact Cascade Gasket to learn more about our full capabilities and to discuss your needs.