Nickel Aluminum Silicone EMI O-Rings
68-durometer. Resists galvanic corrosion. Low outgassing per ASTM E595. Independently tested to MIL-DTL-83528.
Specialty Silicone Products (SSP) manufactures high-performance EMI O-rings that combine electromagnetic interference (EMI/RFI) shielding with environmental sealing against dust, moisture, fuels, and harsh chemicals.
We supply electrically conductive O-rings in standard AS568 dimensions, MIL-DTL-83528 slash sizes (including /002 and M83528/005), and fully custom cross-sections. All materials are compound-formulated, extruded, molded, and tool-fabricated in-house at our ISO 9001:2015 certified facility in Ballston Spa, New York.
An EMI O-ring (electrically conductive O-ring) is a circular elastomeric seal impregnated with conductive metal fillers (such as silver-aluminum, nickel-graphite, or silver-copper) designed to fit into a groove and compress to provide simultaneous electromagnetic interference (EMI/RFI) shielding and environmental sealing (moisture, dust, fuel, or chemical barrier).
Base Elastomers: Silicone, Fluorosilicone (FVMQ)
Conductive Fillers: Silver-Aluminum (Ag/Al), Silver-Copper (Ag/Cu), Silver-Nickel (Ag/Ni) Nickel-Graphite (Ni/C), Nickel-Aluminum (Ni/Al)
Standard Sizing: MIL-DTL-83528 slash sizes (M83528/002, M83528/005), AS568 Standard Dash Sizes, Custom Profiles
Military & Aerospace Specs: MIL-DTL-83528 QPL Certified (Types A, B, C, D, K), Low Outgassing per ASTM E595
Volume Resistivity (VR): 0.0009Ω-cm to 0.100Ω-cm
Operating Temperature: -55°C to 160°C (application dependent)
Manufacturing Processes: Compression Molding, Continuous Extruded Cord, Hot Vulcanized / Spliced
Selecting the proper conductive silicone elastomer depends on your required volume resistivity (VR), shielding attenuation, galvanic corrosion requirements, and fluid exposure. Fluorosilicone base materials add fuel, solvent, and chemical resistance.
| Conductive Filler Type | Base Elastomer | Hardness (Shore A) | Typical Volume Resistivity (Ω-cm) | MIL-DTL-83528 Type Match | Primary Application Advantage |
| Silver-Aluminum (Ag/Al) | Silicone | 65 | 0.003Ω-cm | Type B (QPL) | High attenuation, space-grade low outgassing |
| Silver-Aluminum (Ag/Al) | Fluorosilicone | 70 | 0.003Ω-cm | Type D (QPL) | High attenuation with fuel/solvent resistance |
| Nickel-Graphite (Ni/C) | Silicone | 68 | 0.100Ω-cm | Type C / Type K | Cost-effective, high galvanic corrosion resistance |
| Nickel-Graphite (Ni/C) | Fluorosilicone | 60 | 0.100Ω-cm | Meets MIL-DTL-83528 | Corrosion & fuel resistance for harsh environments |
| Silver-Copper (Ag/Cu) | Silicone | 65 | 0.003Ω-cm | Type A (QPL) | Maximum electrical conductivity & EMP protection |
| Nickel-Aluminum (Ni/Al) | Silicone | 68 | 0.100Ω-cm | Commercial / Mil-Grade | Galvanic compatibility with aluminum enclosures |
Conductive silicone O-rings from SSP include fluorosilicone EMI shielding O-rings and nickel-graphite silicone conductive O-rings.
Contact us for help with material selection and to discuss your conductive O-ring groove design. We make high-attenuation EMI seals.
68-durometer. Resists galvanic corrosion. Low outgassing per ASTM E595. Independently tested to MIL-DTL-83528.
60-durometer. Tested to MIL-DTL-83528. Fuel and solvent resistance.
68-durometer. Resists galvanic corrosion. Independently tested to MIL-DTL-83528 and ASTM B117.
70-durometer. M83528 QPL. Low outgassing. Independently tested to MIL-DTL-83528 and ASTM E595. Fuel and solvent resistance.
65-durometer. M83528 QPL. Low outgassing. Independently tested to MIL-DTL-83528 and ASTM E595.
72-durometer. Resists galvanic corrosion. Independently tested to MIL-DTL-83528. Fuel and solvent resistance.
SSP fabricates conductive O-rings to match military specification requirements:
M83528/002 EMI O-rings (Solid O-Rings): Standard with Solid Circular Cross-Section
M83528/005 EMI O-rings (Non-Standard/Custom ORings): Non-Standard with Custom Inner Diameters and Cross-Sections)
We produce conductive silicone and fluorosilicone O-rings matching standard AS568 EMI O-rings to fit standard commercial gland dimensions without requiring custom enclosure redesigns.
SSP manufactures direct drop-in material alternatives for leading industry brands, offering low minimum order quantities (MOQs), shorter lead times, and direct factory support.
Alternatives to Parker Chomerics CHO-SEAL®: Drop-in conductive elastomers for CHO-SEAL 1212, 1215, 1285, 1287, 1298, 6305, 6502, and 6503.
Alternatives to Discontinued W.L. Gore® Materials: Drop-in replacement materials for discontinued UL 94 V-0 flame-resistant EMI shielding options, including GORE GS2100 and GS5200.
Alternative to Nolato Jabar Materials: Drop-in replacements for 805, 815, 802 series, 812, 806-A, 816, 806-K, 822
(CHO-SEAL® is a registered trademark of Parker Hannifin Corporation. Gore® is a registered trademark of W.L. Gore & Associates, Inc. SSP is an independent manufacturer.)
SSP offers two primary manufacturing methods for conductive O-rings depending on budget, volume, lead time, and cross-section requirements.
Compression molding creates a continuous, single-piece O-ring with no splice joint. It is best suited for mature designs, tight inner diameters, or high-volume production runs where tooling costs ($2,500–$5,000 per mold) are amortized over large quantities.
For prototyping, low-to-medium volume production, or large-diameter enclosure seals (developed lengths of 7 inches or greater), hot splicing extruded conductive cord stock eliminates expensive mold tooling charges and reduces lead times from months to days.
Electrically Conductive Adhesive: Unlike competitors who use non-conductive RTV silicone or cyanoacrylate (super glue)—which leaves an EMI leakage pathway—SSP hot-vulcanizes the joint using a matching conductive silicone adhesive.
No Hard Spots: Cold acrylic glues dry rock-hard, creating a stiff section along the O-ring that hinders uniform compression. SSP’s hot-spliced adhesive matches the durometer and flexibility of the base conductive elastomer.
Thermal Resistance: Our conductive vulcanized joint withstands the full $-55^\circ\text{C}$ to $+160^\circ\text{C}$ operating temperature range of the cord stock.
A standard rubber O-ring provides environmental sealing (blocking fluids, dust, and gases) but is an electrical insulator. A conductive EMI O-ring is loaded with microscopic metal particles that allow electrical current to pass through the gasket, grounding the enclosure and blocking electromagnetic radiation (RFI/EMI) while maintaining environmental sealing.
Choose Silver-Aluminum (Ag/Al) when high shielding effectiveness ($100+\text{ dB}$ attenuation) and MIL-DTL-83528 QPL certification are required, particularly in aerospace and military applications. Choose Nickel-Graphite (Ni/C) when high galvanic corrosion resistance against aluminum flanges is critical, or for cost-conscious commercial applications requiring strong shielding performance ($90+\text{ dB}$).
Select silicone for general military, aerospace, and commercial applications requiring broad thermal tolerance ($-55^\circ\text{C}$ to $+200^\circ\text{C}$) and weather resistance. Select fluorosilicone (FVMQ) if the O-ring will come into direct contact with fuels, hydraulic fluids, solvents, or oils.
Need custom conductive O-ring dimensions, assistance with groove design, or drop-in CHO-SEAL® alternatives? SSP offers rapid turnaround on prototype samples, low minimum order quantities, and direct engineering support.
Contact Specialty Silicone Products Today:
Phone: 800-437-1442 / 518-885-8826
Location: Ballston Spa, NY (Made in USA)
Response Time: We typically reply to all engineering inquiries within one business day.