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Form-in-Place Gaskets (FIPG): Reducing Downtime and Assembly Errors in Production Lines

Form-in-Place Gasket (FIPG) sealants are one-component liquid gaskets applied to a flange or mating surface that cure after assembly, forming a flexible, conformal seal. Unlike pre-cut solid gaskets, FIPG beads spread into surface irregularities and cure in place, providing 100% contact between mating parts. ThreeBond’s FIPG adhesives – ranging from rubber base / synthetic rubber to olefin/acrylic chemistries (1100/1150 series) to silicone RTVs (1200 series) – have long been used in automotive and industrial manufacturing. These liquid gaskets eliminate the need to inventory many solid gaskets and avoid manual placement errors, making them ideal for high-volume assembly lines.

Technical Advantages of Form-in-Place Gaskets (FIPG) vs. Traditional Gaskets

FIPG sealants offer several technical benefits over conventional pre-formed gaskets. Because the liquid gasket fills the flange gap and cures to an elastomeric seal, it compensates for surface irregularities and wide tolerances that would challenge a solid gasket. In practice, a properly dispensed liquid gasket “provides 100% contact between mating… surfaces”, preventing leaks of oil, coolant or gas. The cured FIPG also absorbs vibration and cushions shock loads, and even acts as an EMI (electro-magnetic interference) shield where needed. By comparison, cutting and fitting a hard gasket can leave voids or misalignments; FIPG “seals rippled surfaces better and compensates for larger production tolerances”.

Because FIPG materials react in place, no external compression is needed at assembly. ThreeBond’s silicone FIPG products (the 1200 series) form a rubber-elastic seal that bonds to metals and plastics without corroding them. For example, the TB1207B, TB1216E and TB1217 series are high-temperature silicone gaskets (–60 to +250°C) designed for engine oil pans and pumps. These sealants are formulated (with oxime, acetone or alcohol cure chemistries) to cure smoothly into a flexible “no-compression” gasket. In contrast to rigid gaskets, FIPG cures into a continuous bead that requires no tightening torque and tolerates differential movement, reducing risk of joint failure.

ThreeBond also offers TB1153E, a high-performance FIPG sealant engineered for extreme environments such as satellites, delivering excellent gas barrier properties, heat resistance, and moisture control—ideal for fuel cell batteries and thermal management systems in aerospace and space-grade applications. Other examples include TB1184, a solvent-curing general-purpose gasket for large clearances, and TB1222C, an incombustible RTV silicone (UL94V-0) rated to +250°C. By selecting the chemistry and viscosity suited to each flange (metal type, fluid, gap, etc.), ThreeBond’s FIPG system ensures a durable, leak-proof seal under diverse conditions.

Efficiency Gains and Error Reduction on Assembly Lines

Switching to FIPG can dramatically improve assembly efficiency and quality. Because liquid gaskets are dispensed – often by automated valves or robots – manufacturers avoid the time-consuming tasks of ordering, stocking and fitting die-cut gaskets. In practice, “liquid gaskets shorten lead times and lessen the need for inventory, and their application is easy to automate”. For example, one electronics enclosure maker replaced manual syringe dispensing of silicone gasket with an automated dispenser, which immediately met production demand by eliminating human variability. The controlled dispense ensures a consistent bead each cycle, so “FIP gaskets are precisely dispensed every time with almost no wasted material”. This precision virtually eliminates common assembly errors such as missing, misaligned or damaged gaskets that occur with manual installation.

On the line, FIPG also reduces downtime from rework and testing. Because the bead spreads into minor surface defects, it forms a complete seal without torque adjustments or leak-testing multiple times. In high-volume plants, engineers often run an inline pressure test immediately after assembly; the robust FIPG bead withstands partial curing during test pressure if flange design is correct. Unlike slower-curing adhesives, many ThreeBond FIPG formulations harden quickly enough for line-speed assembly. (Note that traditional FIPG is a room-temperature cure, but ThreeBond also offers rapid-curing grades and even UV-curable variations for faster throughput). Overall, the combination of 100%-contact sealing and automated dispensing means faster cycle times, fewer leaks in service, and less scrap – all of which boost uptime and reduce costs.

Industrial Use Cases: Automotive, Heavy Machinery and OEMs

FIPG technology is used across the manufacturing spectrum. The automotive industry pioneered FIPG for engine and transmission assembly, and ThreeBond continues to serve OEMs and Tier-1s in that space. For example, ThreeBond FIPG silicones are widely used on engine oil pans, gearbox cases and water pumps in cars and trucks. The adhesives & sealants markets note that “most manufacturers have replaced traditional die-cut or molded gaskets with form-in-place” liquid gaskets in vehicles, appliances and electronics. ThreeBond products such as TB1207B, TB1216E and TB1227D are explicitly formulated for engine oil and cooling liquid sealing in automotive applications.

Beyond automobiles, FIPG is found in heavy machinery and OEM production. Any equipment with fluid pumps, gear reducers or hydraulic systems can benefit. For instance, agricultural machinery and construction equipment – which often have large cast flanges – use FIPG to seal transfer cases and hydraulic housings, taking advantage of the sealant’s ability to fill wide gaps. ThreeBond notes that 1200-series silicones and modified silicones (e.g. the TB1200 and TB1206 series) are suitable for general machines, while specialized grades exist for PVC pipes or fuel cells.

FIPG is also critical in emerging technologies. In electronics enclosures and small engines, ThreeBond FIPG adhesives replace pre-cut gaskets to simplify assembly and improve reliability. Across all these industries – from powertrain to appliances – the common benefit is a durable, leak-proof joint with fewer assembly hiccups and faster throughput.

ThreeBond FIPG Product Lineup and Applications

ThreeBond offers a comprehensive range of FIPG sealants (non-silicone and silicone-based) for virtually every flange sealing need. Notable products include:

• TB1121 (1100-series, gray liquid gasket): A non-drying, all-purpose FIPG recommended for machine joints and general flanges. It is often used with solid gaskets to ensure leak-free seals in transmission and pump housings.
  
• TB1184 (1100-series, solvent-based gasket): A brown, solvent-vaporizing all-purpose liquid gasket. It works well on large flanges and threaded connections, sealing against water, oil and gasoline (stable from –40°C to 150°C).
  
• TB1207B (1200-series, black silicone): A room-temperature vulcanizing silicone FIPG with very high heat/cold resistance (–60°C to +250°C). It is non-corrosive and is primarily used for sealing engine oil pans, cylinder blocks and water pumps.
  
• TB1211 (1200-series, white silicone): A low-viscosity, neutral-cure RTV FIPG known for its excellent oil resistance. It is often used with pre-cut gaskets (e.g. in differential covers or transmission cases) to provide a backup seal.
  
• TB1215 (1200-series, gray silicone): A multipurpose silicone liquid gasket with high heat and gear-oil resistance. It is used in gearboxes and engine components where oil compatibility is needed.
  
• TB1216E (1200-series, gray silicone): A high-temperature, moisture-curing RTV FIPG. It offers excellent initial pressure resistance and chemical resistance, and is recommended for engine oil pan sealing and pump housings.
  
• TB1217F (1200-series, gray silicone): Similar to TB1216E, this grade is engineered for engine and pump sealing. It cures rapidly to a flexible gasket and is also used on oil pans and water pumps.
  
• TB1217H (1200-series, gray silicone, high-viscosity): A high-modulus FIPG silicone with outstanding blow-out resistance and elongation. It is designed for powertrain joints under vibration, such as differential covers and heavy-duty engine pans.
  
• TB1217M (1200-series, black silicone): A silicone FIPG with enhanced adhesion for oily or low-energy surfaces. It excels on magnesium or aluminum engine blocks and is used for oil pan and chaincase sealing in motorcycles and small engines.
  
• TB1227D (1200-series, black silicone): A general engine FIPG with high oil and coolant (LLC) resistance. It is commonly used on engine oil pans, timing covers and other large housings.
  
• TB1222C (1200-series, gray silicone, flame-retardant): An RTV sealant meeting UL94V-0, rated –60°C to +250°C. It is intended for high-heat applications requiring flame resistance, such as electronic module housings and engine compartments.
  
• TB1225B (1200-series, white silicone): A thermally conductive FIPG silicone formulated for electrical assemblies. It bonds PCBs and heat sinks, and is used in power electronics and switchgear for its ability to dissipate heat while sealing.

Each of these ThreeBond FIPG products is backed by technical datasheets and has been selected for its specific fluid compatibility, temperature range and joint conditions. By choosing the appropriate FIPG for the job, manufacturers achieve a reliable seal in one step – significantly reducing assembly errors and downtime.

Conclusion

Form-in-Place Gasket technology transforms sealing in assembly operations. By dispensing ThreeBond FIPG sealants directly onto mating surfaces, OEMs eliminate gasket mismatch, reduce inventory and ensure a leak-tight seal every time. These liquid gaskets conform to any geometry and cure into durable elastomers, which prevents leaks, vibration damage and rework. The result is higher uptime: assembly lines run faster with fewer interruptions, and products leave the line ready for service. ThreeBond’s wide FIPG portfolio (see table above) gives engineers precise control over sealing performance – helping automotive, heavy machinery and industrial OEMs cut downtime and boost quality in their production lines.