When qualification of critical sealing components required an alternative approach, Stockwell Elastomerics delivered engineered silicone solutions with integrated conductivity and strong first-pass sample performance. Hands-on engineering support and production-ready planning enabled a smooth recovery and a clear path to qualification and scale.
Application Overview
Application: Artillery fuse assembly
Environment: High shock, vibration, thermal cycling, and long-term storage
Requirements:
- Reliable environmental sealing
- Integrated conductivity
- SSP / AMS-compliant silicone materials
- ITAR and AS9100-certified manufacturing
Artillery fuses present extreme mechanical and environmental demands, requiring elastomeric components that maintain compression, dimensional stability, and electrical performance throughout the system lifecycle.
The Challenge
During the initial validation phase, the first silicone sealing solution presented challenges in meeting SSP qualification requirements, prompting additional testing and engineering review. These activities extended the evaluation timeline as the team worked to establish confidence in long-term sealing performance.
Key challenges included:
- Achieving consistent first-article performance
- Managing sealing and conductivity in a compact assembly
- Establishing a predictable development and ramp plan
The Stockwell Solution
Engineered Material and BOM Strategy
Stockwell supported a controlled BOM approach using SSP-qualified silicone materials, including AMS 3302-class compounds around 50 Shore A durometer. The strategy balanced performance consistency with supply-chain resilience while meeting defense material requirements.
Typical performance attributes included:
- Temperature resistance from −55 °C to +200 °C
- Low compression set for long-term sealing integrity
- Stability under shock, vibration, and storage conditions
Advanced Manufacturing Capability: Co-Molded Silicone with Conductive Puck
A key differentiator was Stockwell’s ability to support co-molded silicone components with an integrated conductive puck, combining environmental sealing and electrical conductivity control into a single engineered assembly.
This approach:
- Reduced part count and assembly complexity
- Improved reliability under high-G loading
- Ensured consistent compression and grounding continuity
- Minimized interface-related failure modes
Engineering Support and Development Approach
Stockwell acted as an extension of the customer’s engineering team by providing:
- Early design and material reviews focused on form, fit, and function
- Direct engineering support during sample development
- A defined development plan with clear ramp and production considerations
- Design-for-manufacturability feedback to ensure repeatability at scale
Results and Success Measures
High First-Pass Sample Success
Initial samples met performance expectations with minimal iteration, immediately restoring confidence after the previous qualification failure.
Clear Path to Qualification and Production
Consistent sample quality, combined with transparent development and ramp planning, enabled a smooth transition toward qualification readiness.
This program demonstrates that in defense applications, qualification success depends on both material performance and engineering partnership. Stockwell’s combination of certified compliance, advanced elastomeric manufacturing, and responsive engineering support allowed a stalled sealing effort to recover quickly and move forward with confidence.
If your program involves high-reliability silicone sealing, integrated conductivity and EMI solutions, or demanding qualification timelines, engage Stockwell early.
Request a rapid prototype or consult with a Stockwell application engineer to de-risk qualification and accelerate readiness.
