Custom Non-Metal & Plastic Gaskets for Electrical Insulation

At ESPE, we manufacture a variety of custom electrical insulation products and components, including plastic gaskets, using a wide range of fabrication methods to meet the most stringent industry standards, including ANSI, ASTM, and ISO. Our 30,000 square foot state-of-the-art design and fabrication facility is capable of producing products derived from hand sketches or image files in AutoCAD, IGES, AutoWorks, and a variety of other programs. With decades of experience and an extensive portfolio of technologically advanced equipment, we can design and manufacture custom gaskets for electrical insulation using a wide variety of materials.

Custom Laser-Cut Plastic Gaskets

A gasket is a type of sealing hardware composed of a pliable material such as plastic or rubber that is cut to fit around equipment openings and joints. Gaskets are used to create an air-tight seal between components to prevent liquids and gases from leaking around the seam. Depending on the application for which they are designed, gaskets are manufactured in a variety of shapes and sizes from materials that are resistant to high pressure, extreme temperatures, electrical current, and other potentially compromising environmental factors.

Natural and synthetic rubbers and elastomeric polymers, such as polyvinyl chloride (PVC), are common materials used for gasket seals. The elastomeric properties of these materials allow them to withstand compression and deformation while retaining material stability and integrity.

In electronic applications, gaskets are specifically designed to insulate sensitive electronic components from external environmental conditions such as moisture and temperature fluctuations. They also keep electrical current contained within electrical housings, thereby reducing the risk for damage and injury due to unwanted electrical flow. The correct electrical gasket creates a reliable seal in both indoor and outdoor applications throughout its service life. Gaskets used for electrical applications must also meet particular industry specifications, such as Underwriters Laboratories (UL), National Electrical Manufacturers Association (NEMA), and Ingress Protection (IP) standards in order to be considered safe for use.

Advantages of Laser Cutting Gaskets

ESPE’s laser cutting services offer a high degree of accuracy within exceptionally tight tolerances. With the latest in laser cutting technology, we can create electrical gaskets quickly and efficiently with a high level of precision. Laser cutting offers numerous benefits over other cutting methods, including:

  • No tooling costs
  • Quick turnaround times
  • Prototyping different sizes, materials, patterns
  • Highly precise cuts with tight tolerances
  • No compression distortion
  • Nested cutting arrangements for improved material yield

ESPE is also pleased to offer quality die-cutting services for electrical gasket manufacturing. Although die cutting tools must be pre-fabricated, they efficiently produce quick, accurate, and highly repeatable finished products. This method is preferable for use in large scale, high-volume production where speed and precision are paramount.

A Sample of the Materials We Work With

ESPE specializes in the development and production of a wide range of electronic components from multiple plastic and non-metal materials. Although our portfolio of materials is extensive, the most common materials used for custom cut gaskets include:


Nylon is a smooth thermoplastic material valued for its high level of flexibility, strength, and resistance to abrasion, impact, and compression. It is not affected by moisture, and is resistant to mold and mildew, as well as a wide variety of chemicals, oils, and greases. Different nylon formulations and blends are often used to enhance certain physical characteristics, such as thermal and electrical conductivity, tensile strength, rigidity, and chemical resistance.


Polytetrafluoroethylene (PTFE), also known as Teflon®, is a synthetic fluoropolymer manufactured by DuPont. It exhibits a number of valuable traits, including extreme chemical resistance, hydrophobic properties, very low friction coefficient, and exceptional electrical and thermal insulation properties. It is FDA and AMS compliant, which makes it ideal for use in medical, pharmaceutical, and food and beverage applications.


Kapton® is a highly temperature-resistant polyimide film with exceptional tear strength, toughness, and dielectric properties. It’s electrical insulative properties coupled with thermal and chemical resistance make it perfect for use in printed circuit boards and electronics exposed to extreme conditions.


Lexan®, also known as polycarbonate, is a clear, impact-resistant plastic that exhibits excellent thermal and electrical insulation characteristics. It is extremely tough, flexible, and shows very high dimensional stability under pressure. In addition to its electrical insulative properties, Lexan is flame retardant, with UL94 V-0 and VTM-O ratings.


Delrin®, or Acetal, is a thermoplastic polymer derived from formaldehyde. It is valued for its lightweight strength and structural stability. It is often used as a replacement for metal components in weight-sensitive applications. Delrin® displays exceptional chemical, heat, and moisture resistance, and has a low coefficient of friction.

Top Quality Non-Metal and Plastic Gaskets From ESPE Manufacturing Co., Inc.

At ESPE, we pride ourselves on providing the highest quality non-metal custom gaskets for our customers in every industry. We offer an extensive variety of custom rubber and plastic gaskets and other electrical insulation products tailored to meet even the most rigorous industry specifications. To learn how ESPE’s electrical insulation solutions can improve your operations, contact us today.