Cavity Count
2 - 40 Way
Protection
IP67/IP68/IP69K
Temperature
-40°C to +200°C
Hardness
30-60 Shore A
Mat Seals Manufacturer India — Connector Family Seals & Multi-Cavity Wire Harness Seals
A mat seal is a single moulded rubber component that seals every wire entering a connector at once. Instead of fitting an individual seal to each terminal, one mat seal drops into the rear of the connector housing and its moulded passageways close around each wire simultaneously. This is why mat seals are also called family seals — one part serves the whole family of circuits in that connector.
ARPL manufactures mat seals from 2-way to 40-way in inline strip, rectangular grid and profiled ECU footprints, in LSR and HCR silicone, NBR, HNBR, EPDM and FKM. Every passageway carries multi-lip sealing geometry and the seal perimeter is beaded against the housing bore, delivering IP67 and IP68 protection as standard and IP69K on selected designs. All parts are validated to USCAR-2 and LV214 and supplied with full PPAP documentation from our IATF 16949:2016 certified plant at IMT Manesar.
Available Mat Seal Materials
We manufacture mat seals and family seals in all of the above materials, including self-lubricating silicone grades that reduce wire insertion force on automated harness lines. Custom hardness (30-60 Shore A typical), colour coding and cavity layouts are developed to your drawing.
About ARPL Mat Seals (Connector Family Seals)
ARPL is a leading Indian manufacturer and exporter of automotive mat seals — the one-piece, multi-cavity elastomeric seals that sit at the rear of a sealed connector and protect every circuit in it. Our mat seals are supplied to automotive OEMs and Tier-1 wiring harness manufacturers for engine bay, chassis, body and electric vehicle applications where connectors must survive water, road spray, dust, oil, salt and constant vibration for the life of the vehicle.
Mat Seal, Family Seal, Multi-Cavity Seal — the Same Component, Different Names
Terminology for this component varies by region and by customer, which often makes sourcing confusing. Mat seal is the usual term in North American and Asian connector catalogues. Family seal is standard in European technical documents and among Tier-1 harness makers. Some drawings call it a multi-cavity seal, a connector rear seal, or a grommet seal. All describe the same part: a moulded rubber mat with a plurality of wire passageways that seals a complete connector interface in one piece. ARPL manufactures the full range under every one of these names.
Mat Seal vs Single Wire Seal — Which Should You Specify?
The choice between a mat seal and individual single wire seals (SWS) shapes both your connector design and your harness assembly process. A single wire seal is fitted to each terminal and inserted with its wire, so a 12-way connector requires twelve seals and twelve insertion operations. A mat seal is one part, normally pre-assembled into the housing, that seals all twelve cavities together.
Mat seals reduce part count and line-side inventory, cut assembly time, and allow a materially smaller connector body because there is no need to accommodate a seal barrel on every terminal. Single wire seals, in exchange, apply higher sealing force per cavity and let individual circuits be repaired or re-terminated in service without disturbing the rest of the connector. Most modern high-density connectors — particularly ECU and body control module interfaces — use mat seals for exactly these packaging reasons. ARPL manufactures both, and our engineers will advise which fits your connector geometry, IP target and harness process.
Blanked Cavities — Sealing Unused Positions Without Cavity Plugs
One of the strongest practical advantages of a mat seal is how it handles unpopulated circuits. ARPL mat seals can be moulded with blanked cavities — passageways closed by a thin membrane. Unused positions remain sealed with no additional part and no assembly operation, and the membrane is pierced by the terminal only when that circuit is actually populated. For a connector family where a single housing serves several vehicle variants, this eliminates the cavity plugs and dummy plugs that would otherwise be needed in every empty position. Where a design must allow circuits to be added later in service, we also supply open-cavity mat seals with matching plugs.
Sealing Geometry & Manufacturing Capability
Each wire passageway in an ARPL mat seal carries multiple internal sealing lips, creating redundant barriers against water and contaminant migration along the wire insulation. The outer perimeter is moulded with a sealing bead that compresses against the connector housing bore, closing the second leak path. Cavity pitch, lip diameter and interference are matched to the specified wire gauge range, and a single mat seal can carry mixed cavity diameters where a harness combines signal and power circuits.
Production runs on LSR injection moulding, compression and transfer moulding, with cryogenic deflashing for burr-free passageways — critical on a mat seal, where flash in a cavity directly causes an insertion failure or a leak path. Dimensional control is held to ±0.05mm and verified on vision measurement systems. Every batch is subject to leak testing, wire insertion and retention force testing, compression set and thermal cycling, to USCAR-2 and LV214 protocols with ingress classification referenced to ISO 20653 and IEC 60529.
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Mat Seal FAQ — Specifications, Materials & Sourcing
Common questions about mat seals, family seals and multi-cavity connector sealing
A mat seal is a single moulded rubber component with multiple wire passageways that seals every wire entering an automotive connector at the same time. It sits in the rear of the connector housing, and each passageway carries internal sealing lips that grip the wire insulation. Because one mat seal replaces a whole set of individual wire seals, it reduces part count, shrinks the connector package, and speeds up harness assembly. Mat seals are also called family seals, multi-cavity seals, or connector rear seals.
A single wire seal (SWS) is one small seal fitted to one terminal and inserted with that wire, so a 12-way connector needs 12 separate seals and 12 insertion operations. A mat seal is one part that seals all 12 cavities at once and is normally pre-assembled into the housing. Mat seals cut part count and assembly time and allow a smaller connector body, while single wire seals give higher per-cavity sealing force and let each circuit be serviced independently. ARPL manufactures both — see our wire seals range — and our engineering team will advise which suits your connector and harness process.
Yes. Family seal and mat seal describe the same component — a one-piece multi-cavity elastomeric seal for a connector rear. Terminology varies by region and by OEM: European technical documents and many Tier-1 harness makers say family seal, North American and Asian connector catalogues usually say mat seal, and some drawings call it a multi-cavity seal, grommet seal, or connector rear seal. ARPL supplies the full range under all of these names with complete PPAP documentation.
ARPL manufactures mat seals in LSR (liquid silicone rubber) and HCR silicone for wide temperature range and low compression set, NBR and HNBR for oil and fuel resistance, EPDM for weather and ozone resistance, and FKM (Viton®) for aggressive chemicals and sustained high temperature. Silicone is the most common choice because a mat seal must stay elastic across many cavities for the life of the vehicle. Self-lubricating grades are available to reduce wire insertion force on automated harness lines.
ARPL mat seals are engineered for IP67 and IP68 as standard, with selected designs and materials qualified to IP69K for high-pressure, high-temperature washdown. The rating is achieved through multi-lip wire passageways, a peripheral sealing bead against the housing bore, and dimensional tolerances held to ±0.05mm. Performance is validated to USCAR-2 and LV214 protocols, with reference to ISO 20653 and IEC 60529 for ingress classification.
Mat seals can be moulded with blanked (closed) cavities covered by a thin membrane. Unused positions stay sealed with no extra part, and the membrane is pierced by the terminal only when that circuit is populated. This removes the need for separate cavity plugs or dummy plugs in most designs. Where a connector family must support later circuit additions in service, ARPL can supply open-cavity mat seals together with matching cavity plugs.
ARPL manufactures mat seals from 2-way up to 40-way and above, in inline strip, rectangular grid, and profiled ECU footprints, with mixed cavity diameters on a single seal for harnesses that combine signal and power circuits. Seals are produced to customer drawings or reverse-engineered from samples, including colour coding by wire gauge or connector family.
For an existing ARPL mat seal tool, first PPAP supply is typically 4-6 weeks and repeat production 2-3 weeks. A custom mat seal developed from drawings or samples takes approximately 8-12 weeks including tooling, DV and PV testing, and PPAP submission. MOQ depends on cavity count, material, and tooling status — contact our team with your drawing for a specific quotation.
Yes. ARPL is ISO 9001:2015 and IATF 16949:2016 certified and exports mat seals and family seals to the USA, Germany, Mexico, Thailand, Vietnam, Turkey, UAE, Brazil, Poland, Czech Republic, and Hungary. All products are REACH and RoHS compliant with export documentation prepared for smooth customs clearance.
ARPL manufactures mat seals at Plot No. 90, Sector 6, IMT Manesar, Gurugram, Haryana 122052, India. The plant produces over 50 million rubber sealing components per month and is IATF 16949:2016 and ISO 9001:2015 certified, supplying automotive OEMs and Tier-1 wiring harness manufacturers in India and worldwide.