Mid-Atlantic Rubber Inc
Custom Gaskets & Foam Products
Precision Water Jet Cut Solutions. No Dies. No Setup Charges. No Minimums.
Custom Gaskets & Foam Products
Every application has unique sealing and cushioning requirements. Off-the-shelf gaskets and foam products rarely deliver the exact fit, material, or performance your project demands. That’s why manufacturers across the Mid-Atlantic and beyond turn to Mid-Atlantic Rubber (MAR) for custom gaskets and foam products built precisely to their specifications.
Using advanced water jet cutting technology, we produce custom gaskets and foam components up to 8 inches thick from virtually any rubber, plastic, foam, or sponge material. And because water jet cutting eliminates the need for costly dies, you never pay design fees, setup charges, or tooling costs. Whether you need a single prototype or a production run of thousands, we deliver the same precision and quality on every order.
Custom Gaskets & Foam Products
Why Manufacturers Choose MAR for Custom Gaskets
Water jet cutting gives MAR a significant edge over traditional die-cutting methods. Our process uses high-pressure water streams (and abrasive particles when needed) to cut through materials with exceptional accuracy without generating heat, mechanical stress, or material distortion.
Custom Gaskets & Foam Products
Here’s what that means for your project:
No Die Costs
No Setup Charges
Material Versatility
Up to 8” Thick
No Heat-Affected Zones
Prototype to Production
Custom Gaskets & Foam Products
Materials We Work With
MAR stocks and cuts a wide range of materials to meet the demands of industries from aerospace and defense to HVAC and food processing. Some of the most commonly requested materials include:
Gasket Materials
- Natural Rubber
- Neoprene / CR
- EPDM
- Silicone
- Viton / FKM
- Nitrile / Buna-N
- PTFE / Teflon
Foam & Specialty Materials
- Closed-Cell Neoprene Foam
- Polyethylene Foam
- Silicone Foam
- Polyurethane Foam
- Cross-Linked PE Foam
- Cork & Cork-Rubber Composites
- Compressed Non-Asbestos Fiber
Custom Gaskets & Foam Products
Industries We Serve
Our custom gaskets and foam products are used across a broad range of industries where reliable sealing, cushioning, and insulation are non-negotiable:
- Military & Defense
- Aerospace
- Medical Devices & Equipment
- HVAC & Mechanical Systems
- Automotive & Heavy Equipment
- Food & Beverage Processing
- Electronics & Electrical Enclosures
- Industrial Manufacturing
Case Study
Solving a Critical Seal Failure for a Regional HVAC Manufacturer
Client Name
Crestline Thermal Systems
Industry
Commercial HVAC
Location
Richmond, VA
Custom Gaskets & Foam Products
The Challenge
Crestline Thermal Systems designs and assembles commercial rooftop HVAC units for mid-size office buildings and retail facilities across the Southeast. In early 2024, their engineering team flagged a recurring problem: the flange gaskets sealing the blower housing on their CTX-400 series were failing prematurely.
The off-the-shelf EPDM gaskets they’d been sourcing from a catalog supplier were compressing unevenly under the bolted flange connections. After 8 to 12 months of thermal cycling and continuous vibration, the gaskets were losing their seal. The result was air leakage that reduced system efficiency by as much as 15%, which led to increased energy costs and warranty callbacks from their commercial clients.
Crestline’s engineering lead had a clear goal: find a gasket that could withstand sustained temperatures between -20°F and 300°F, maintain a consistent seal under variable bolt torque, and hold up through at least five years of continuous operation. The geometry was the tricky part — the blower housing flange had an irregular profile with multiple bolt holes and a narrow sealing surface that didn’t match any standard gasket dimensions.
Custom Gaskets & Foam Products
The MAR Solution
Crestline reached out to MAR after a recommendation from another Virginia-based manufacturer. After reviewing the CAD drawings and understanding the operating conditions, our team recommended a closed-cell silicone sponge gasket, water jet cut to the exact flange profile.
Here’s why silicone sponge was the right call:
It handles a temperature range of -65°F to 450°F well beyond Crestline’s requirements.
Closed-cell construction resists moisture absorption and maintains consistent compression over time.
Silicone sponge has excellent compression set resistance, meaning it bounces back after repeated compression cycles rather than flattening permanently like the EPDM gaskets they’d been using.
Our water jet cut the gaskets directly from Crestline’s CAD file, matching the irregular flange geometry and bolt hole pattern precisely. No die was needed, so we had a set of prototypes shipped within five business days of receiving the drawing.
Custom Gaskets & Foam Products
The Results
Crestline installed the MAR gaskets on a batch of CTX-400 units and ran a controlled comparison against units using their previous gaskets. After 12 months of field operation:
Zero Seal Failures
15% Efficiency Gain
40% Cost Reduction
Beyond the performance improvement, Crestline appreciated the simplicity of working with MAR. When they later modified the CTX-400 flange design for a new model variant, updating the gasket was as easy as sending a revised CAD file. No retooling. No delays. Just a new cut file and updated gaskets shipped within the week.
Kevin Morales,
our process
Our Process: From Your Design to Finished Parts
Send Us Your Requirements
Material Recommendation
Water Jet Cutting
Quality Check & Delivery
Ready to Solve Your Gasket Challenge?
Send us your drawing or specs and get a no-obligation quote.