Precision Extruded O-Rings & Custom Cord Stock
Flawless surface finish. Uncompromising shape integrity. Whether you need 50 meters of a custom extruded o ring cord or a definitive solution to high-pressure o ring extrusion failure, RiseUp engineers consistency from the first inch to the last.
Engineered for the Toughest Tolerances
We understand the headaches of sourcing extruded rubber rings. A slightly deformed profile or a microscopic surface bubble can lead to catastrophic leaks in your precision grooves. That’s why our extrusion process is built around absolute control:
• Absolute Shape Integrity: Advanced curing and cooling technology ensures your square profile stays square and your hollow tube stays round—no flattening or shrinkage.
• Flawless Surface Finish: Strict temperature management guarantees a smooth, bubble-free, and mark-free surface, eliminating potential micro-leak paths.
• Material Consistency: We guarantee uniform hardness, density, and physical properties across the entire run, whether it’s 50 meters or 5,000 meters.
• Low Entry Barrier: Need a quick prototype? We offer rapid sampling with Zero Tooling Costs for standard dies and incredibly low minimum order quantities (MOQs).
Unlimited Sizes, Custom Profiles: The Power of Extruded Rings
Are you in the early stages of product development? For Product Design Engineers and Fluid Power Technicians, the prototyping phase requires maximum flexibility and minimal risk. When a standard molded O-ring restricts your equipment design or a standard circular cross-section simply won’t seal your unique gland, our custom extruded rubber rings offer the ultimate engineering freedom.
Instead of injecting rubber into a fixed, expensive steel mold cavity, we force raw elastomer through a precision die to create continuous cord stock. This process unlocks several strategic advantages for your supply chain and R&D process:
• Beyond the Circle (Non-Standard Profiles): Need a square, rectangular, D-shape, X-ring, or a completely hollow tube profile? Extrusion dies allow us to create complex, non-circular cross-sections that traditional molding struggles with, perfectly matching your proprietary groove designs.
• Agility for R&D (Zero Tooling Delay): Stop waiting 4 to 6 weeks for a custom mold. Extrusion dies (tooling) are incredibly inexpensive to produce—and often completely free for standard geometric shapes. This allows your team to rapidly prototype, test, and iterate your fluid systems without blowing the R&D budget.
• Infinite Inner Diameters (ID): By precision-cutting and splicing our extruded cord, we can manufacture an extruded o ring to any inner diameter, from 50mm up to 5 meters or more.
“Need these extruded cords joined into continuous, high-strength loops? Discover our advanced [Spliced and Vulcanized O-Rings] for large-diameter static sealing.”
• Ready for Distributors: For Industrial Consumable Suppliers, we offer continuous bulk cord stock on spools. With our guaranteed batch-to-batch consistency and low MOQs, you can reliably stock the exact extruded rings your local MRO clients need for emergency repairs.
Engineering Hub: Decoding O-Ring Extrusion Failure
We know that many fluid power technicians searching for an extrusion o ring are not looking for cord stock—they are troubleshooting a critical hydraulic or pneumatic leak.
In high-pressure dynamic and static applications, o ring extrusion is one of the most common and catastrophic sealing failure modes. If you’ve opened a hydraulic cylinder and found a seal that looks “nibbled,” shaved, or chewed away on the low-pressure side, you are looking at a classic o ring extrusion failure.
How Does Extrusion Happen?
An O-ring seals by deforming against the hardware when pressure is applied. However, when the system pressure exceeds the physical limits of the elastomer, the rubber behaves like a highly viscous fluid. The immense pressure physically forces the soft rubber material into the microscopic clearance gap between the mating metal surfaces (such as a piston and a cylinder bore).
Over time, or under cyclic pressure pulses, this extruded material is sheared or “nibbled” off, leading to a rapid loss of sealing volume and eventual catastrophic leakage.
The Three Root Causes of Extrusion:
1. Excessive System Pressure: The pressure is simply too high for the chosen seal design.
2. Oversized Clearance Gaps: The machining tolerances of the metal hardware leave a gap that is too wide. (Often caused by hardware expansion under pressure, known as “breathing”).
3. Elastomer is Too Soft: The durometer (hardness) of the rubber is insufficient to resist the pressure-to-gap ratio.
The O-Ring Extrusion Limit Guide & Chart
For product design engineers and fluid power technicians, preventing failure starts at the drafting table. Those searching for an accurate o ring extrusion chart need precise data to design safe hardware clearances.
The likelihood of a seal extruding is governed by the critical relationship between three factors:
1. Fluid Pressure: Higher pressure forces the rubber harder against the gap.
2. Clearance Gap: The diametral gap between the mating hardware (e.g., the space between the piston and the bore).
3. Elastomer Durometer: Harder rubber (e.g., 90 Shore A) resists flowing into the gap much better than softer rubber (e.g., 70 Shore A).
Emergency Repair Solutions: The Vulcanized O Ring Kit
How to Read the Extrusion Limit:
As you can see from the chart, as system pressure increases, the allowable clearance gap drastically decreases. If your operating parameters (Pressure vs. Gap) plot above the curve for your chosen durometer, you have crossed the
o ring extrusion limit.
To bring the system back into the safe zone, you must do one of three things:
• Decrease the gap: Tighten your machining tolerances (which increases manufacturing costs).
• Increase the hardness: Upgrade your extruded rubber rings from 70A to 90A (though this may require more squeeze force to seal).
• Add mechanical support: Use an anti-extrusion ring (Back-up ring) to bridge the gap.
MOQ 500 pcs, Accept Customization for Small Order. Design Products as Your Idea.
The Ultimate Fix: Stop Leaks with Anti-Extrusion Rings
If your fluid power system operates in the “red zone” of our extrusion limit chart, redesigning your metal hardware to tighten clearances can cost thousands of dollars. The most practical and cost-effective solution is upgrading your seal assembly with an anti extrusion ring for o ring applications, commonly known as a Back-up Ring.
How Do They Work?
An anti-extrusion ring is a hard, extrusion-resistant ring installed in the same groove as the O-ring, positioned on the low-pressure side. When high system pressure pushes against the soft O-ring, the O-ring transfers that force to the back-up ring. The rigid back-up ring then expands radially to completely close the clearance gap, acting as an impenetrable physical barrier that prevents the O-ring rubber from being “nibbled” away.
Our Anti-Extrusion Solutions:
Whether you are dealing with extreme hydraulic spikes or sustained high-pressure gas, we manufacture precision
anti extrusion ring o ring pairings in several profiles (Solid, Split/Scarf Cut, and Contoured) to fit your specific assembly needs.
Available materials include:
• Virgin PTFE (Teflon): The industry standard. Extremely low friction, universally chemically compatible, and capable of bridging significant gaps.
• PEEK / Nylon: For ultra-high pressure and extreme temperature environments.
• Hard Elastomers (90 Shore A): Made from our premium extruded cord (NBR or Viton), offering a flexible yet highly extrusion-resistant backing for dynamic applications.
Premium Extruded Cord Materials for Every Environment
Whether you are preventing extrusion in a high-pressure hydraulic cylinder or designing a custom weather seal for an outdoor enclosure, material selection is critical. We maintain a comprehensive inventory of raw elastomers ready for custom extrusion, ensuring we can match the exact chemical compatibility, temperature range, and durometer your application demands.
Standard & High-Performance Elastomers Available:
• Nitrile (NBR): The workhorse of fluid power. Excellent resistance to petroleum-based oils, fuels, and hydraulic fluids. (Standard Durometer: 70A or 90A for high-pressure).
• Viton® (FKM): Designed for extreme environments. Unmatched resistance to high temperatures (up to 200°C) and aggressive chemicals.
• EPDM: The ideal choice for outdoor applications. Provides outstanding resistance to ozone, UV radiation, and severe weather conditions. Highly recommended for custom architectural and automotive seals.
• Silicone (VMQ): Features the widest operating temperature range (-60°C to +230°C) with unparalleled flexibility. Available in FDA-compliant grades for food, beverage, and medical device prototyping.
learn more in our detailed [ Material Guide]
Custom Compounding: Need a specific color, conductive properties, or a unique blend? Our materials engineering team can develop custom rubber compounds tailored to your exact specifications.
Ready to Perfect Your Seal?
Don’t let poor surface finishes, inaccurate cross-sections, or high-pressure extrusion failures compromise your equipment. Whether you are a product design engineer needing a custom extruded profile with zero tooling costs, or a fluid power technician urgently requiring anti-extrusion back-up rings, RiseUp is your ultimate sealing partner.
Provide us with your required dimensions, material, and pressure specifications, and our engineering team will deliver a precise, tailored solution within 24 hours.
• ✔️ Zero Tooling Fees on Standard Dies
• ✔️ Low Minimum Order Quantities (MOQ)
• ✔️ Expert Engineering Support
“Looking for standard, high-volume molded seals or micro-O-rings for dynamic applications? Visit our primary [O-Ring Gaskets] page for our full range of standard sizing and AS568 catalog.”
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Alan Chen
Product Sales Manager & Rubber Specialist at RISEUP
