A Guide to Rubber Material Selection

When it comes to designing rubber components, choosing the right material is critical to ensuring performance, durability, and cost-effectiveness. Rubber compounding—a complex blend of elastomers, fillers, and chemical agents—allows manufacturers to tailor materials for specific mechanical properties, environmental conditions, and chemical resistances.

This guide provides a high-level overview of the most common rubber types used across industries, their operating ranges, and general resistance profiles. For custom compounds or more specific recommendations, contact our engineering team directly.

Why Material Selection Matters in Rubber Design

Rubber compounds vary widely in their:

• Temperature tolerance

• Chemical compatibility

• Weather and ozone resistance

• Abrasion resistance

• Fluid interaction

Selecting the wrong material can lead to premature failure, compromised safety, and increased costs.

1. Neoprene (CR – Chloroprene Rubber)

• Operating Temp: -30°F to 212°F

• Key Traits: Flame-retardant, good weather and ozone resistance, moderate oil resistance

• Strengths: Neoprene offers balanced mechanical properties, making it a go-to material for general-purpose sealing applications. It handles exposure to sunlight, ozone, and moderate chemicals without significant degradation, making it suitable for both indoor and outdoor use.

• Applications: HVAC gaskets, weather stripping, automotive bushings, marine components, belts

• Limitations: Degrades in strong oxidizing agents and solvents like esters and aromatic hydrocarbons.

2. EPDM (Ethylene Propylene Diene Monomer)

• Operating Temp: -40°F to 300°F

• Key Traits: Superior weather, ozone, and aging resistance

• Strengths: EPDM performs well in outdoor environments and can withstand steam, water, and polar chemicals. It’s also highly flexible in cold temperatures and maintains good electrical insulation.

• Applications: Roof membranes, automotive weather seals, steam hoses, water system seals, electrical insulation

• Limitations: Poor compatibility with petroleum-based oils and hydrocarbons, which can cause swelling or degradation.

3. Nitrile / Buna-N (NBR – Nitrile Butadiene Rubber)

• Operating Temp: -30°F to 250°F

• Key Traits: Excellent fuel and oil resistance, solid physical strength

• Strengths: Ideal for environments where rubber will encounter hydraulic oils, fuels, and greases. Its strength and abrasion resistance also make it suitable for high-pressure applications.

• Applications: Fuel hoses, O-rings, gaskets, seals, transmission belts, oil-resistant footwear

• Limitations: Sensitive to ozone, weather, and UV (unless blended with PVC or protected with additives).

4. Silicone (Q, Si – Polysiloxane)

• Operating Temp: -80°F to 420°F

• Key Traits: Unmatched temperature flexibility, food-grade compatibility

• Strengths: Silicone maintains flexibility and resilience in both cryogenic and high-heat applications. It is inert and biocompatible, often used in sensitive or hygienic environments.

• Applications: Food processing gaskets, medical tubing, oven seals, aerospace insulation, LED lighting seals

• Limitations: Poor resistance to oils, fuels, and concentrated acids. Its tensile strength and tear resistance are lower than many alternatives.

5. SBR (Styrene-Butadiene Rubber)

• Operating Temp: -20°F to 212°F

• Key Traits: Good abrasion and impact resistance, economical

• Strengths: SBR is widely used due to its cost-efficiency and decent performance in general-purpose applications. It has good flex and resilience under dynamic stress.

• Applications: Tires, shoe soles, conveyor belts, gaskets, automotive suspension parts

• Limitations: Poor weather and oil resistance; prone to degradation in oily or outdoor environments unless compounded with protective agents.

6. Butyl (IIR – Isobutylene Isoprene Rubber)

• Operating Temp: -60°F to 250°F

• Key Traits: Low permeability to gases, excellent electrical insulation

• Strengths: Butyl excels in airtight sealing and damping applications. It’s also resistant to aging, ozone, and moisture—making it ideal for use in vacuum or insulation systems.

• Applications: Tire inner liners, pharmaceutical stoppers, vibration dampers, HVAC sealing

• Limitations: Poor compatibility with petroleum oils and solvents; can swell and weaken in such environments.

7. Natural Rubber (NR – Isoprene)

• Operating Temp: -60°F to 220°F

• Key Traits: Outstanding elasticity and tensile strength

• Strengths: Known for superior mechanical properties, natural rubber is ideal for dynamic applications requiring resilience, cushioning, and tear resistance.

• Applications: Shock absorbers, bridge bearing pads, mountings, vibration isolators

• Limitations: Weak in environments with oil, ozone, UV, and weather exposure; prone to rapid aging unless treated.

8. Hypalon® (CSM – Chlorosulfonated Polyethylene)

• Operating Temp: -40°F to 320°F

• Key Traits: Extreme weather and acid resistance

• Strengths: Combines Neoprene-like durability with better acid and chemical resistance. It is UV-stable and flame-retardant, making it effective for rugged outdoor use.

• Applications: Tank linings, cable jacketing, roofing membranes, inflatable boats

• Limitations: Susceptible to degradation in strong oxidizing solvents and certain esters or ketones.

9. Urethane (AU, EU – Polyurethane)

• Operating Temp: -40°F to 175°F

• Key Traits: Excellent abrasion and impact resistance

• Strengths: Polyurethane rubbers are known for their toughness, flexibility, and exceptional resistance to cuts and wear—ideal for mechanical or high-friction uses.

• Applications: Industrial wheels, bushings, seals, rollers, protective coatings

• Limitations: Sensitive to high temperatures and certain chemicals, especially acids and aromatic solvents.

10. Viton® / Fluoroelastomer (FPM)

• Operating Temp: -10°F to 400°F

• Key Traits: Elite chemical and high-temperature resistance

• Strengths: Viton is the standard for aggressive chemical environments, including automotive, aerospace, and chemical processing. It handles oils, fuels, and oxidizers with ease.

• Applications: Chemical processing seals, fuel system gaskets, aerospace O-rings

• Limitations: Not ideal for low-molecular-weight ketones and esters; cost is significantly higher than general-purpose elastomers.

11. Fluorosilicone (FSi)

• Operating Temp: -60°F to 350°F

• Key Traits: Fluorinated solvent and fuel resistance with silicone’s flexibility

• Strengths: Combines silicone’s flexibility with enhanced resistance to fuels and solvents, particularly useful in aerospace and aviation applications.

• Applications: Aerospace fuel system seals, high-performance O-rings, chemical-resistant tubing

• Limitations: Limited strength and sunlight resistance; not suitable for brake fluids or hydrazine-based fluids.

12. Hydrogenated Nitrile (HNBR)

• Operating Temp: -22°F to 300°F

• Key Traits: Improved chemical and temperature resistance over NBR

• Strengths: HNBR is a robust upgrade from standard nitrile with better performance in high-heat, oil, and ozone-rich environments. It maintains flexibility and toughness under stress.

• Applications: Automotive seals, oil well components, refrigerant systems

• Limitations: Reduced low-temperature flexibility compared to NBR; not ideal for use with chlorinated hydrocarbons.

13. Carboxylated Nitrile (XNBR)

• Operating Temp: -20°F to 250°F

• Key Traits: Enhanced tear and abrasion resistance

• Strengths: Designed for rugged environments where oil resistance and mechanical strength are critical. XNBR is commonly used in demanding dynamic applications.

• Applications: Industrial rollers, high-wear gaskets, fuel hoses, off-road seals

• Limitations: Fair ozone and UV resistance; performance outdoors may require protective coatings or additives.

📩 Need guidance choosing the right compound? Contact our team for expert assistance in selecting or customizing a rubber formulation that aligns with your performance requirements.