Compression Foam / Gasket Seal Calculator

Calculate compression force, contact pressure, and compression set for foam gaskets and elastomeric seals

Material

Material Type

Gasket Geometry

Uncompressed Thickness(t₀)

Compressed Thickness (gap)(t₁)

Contact Area(A)

mm²

Compression Force Deflection (CFD) Properties

CFD @ 25% Compression(σ₂₅)

kPa

CFD @ 50% Compression(σ₅₀)

kPa

Compression below 25% — seal may leak

Foam gaskets typically require at least 25% compression to achieve reliable sealing. Insufficient compression leads to incomplete surface contact and potential leak paths. Reduce the gap (compressed thickness) or use a thicker gasket.

Under-Compressed

0.00

Compression (%)?

0.00

Required Force (N)?

0.00

Contact Pressure (kPa)?

Force vs. Deflection %

This curve shows how much clamping force (N) your gasket produces at each compression level. The blue dot is your current operating point. The green zone (25–50%) is optimal — enough deflection for a reliable seal without over-stressing the foam. Beyond 50% (red zone) force rises steeply but so does permanent deformation. Use the tolerance band to see how manufacturing variation in the gap affects force.

Compare:

C = 33.33%F = 9.17 Np = 36.67 kPa

Sensitivity: 0.50 N/%(Moderate)

For every 1% change in compression, force changes by ~0.50 N/%.Moderate sensitivity — output responds moderately to input changes.

Tolerance band±mm→ 5.83–12.50 N

Optimal 25–50%Set risk >50%±0.2 mm tolerance

Created by Catlynn Nguyen & Jie Chai · 2026