Wire Range
0.5mm - 50mm
Protection
IP67/IP68
Temperature
-60°C to +200°C
Configurations
Single/Multi
Wire Seals Manufacturer - Single Wire Seals (SWS) & Cavity Plugs
Wire seals are specialized rubber components designed to provide reliable sealing and protection for wires passing through panels, housings, and connectors. These critical components ensure environmental protection against moisture, dust, chemicals, and other contaminants while maintaining cable integrity and preventing damage from vibration or mechanical stress. Our wire seals are engineered to meet the demanding requirements of automotive wire harnesses, electrical enclosures, and industrial cable management systems.
ARPL manufactures a comprehensive range of wire seals suitable for single and multi-wire applications, featuring excellent compression set resistance, superior sealing performance, and long-term durability in harsh environments.
Available Wire Seal Materials
We manufacture Wire Seals and Single Wire Seals (SWS) in all of the above materials including self-lubricating LSR for automated harness assembly. Custom hardness options (40-60 Shore A typical) and specifications tailored to your application requirements.
About ARPL Wire Seals (Single Wire Seals & Cavity Plugs)
ARPL is a leading manufacturer and exporter of high-quality wire seals and single wire seals (SWS), offering innovative sealing solutions for the automotive, electronics, and industrial sectors. Our wire seals are designed to provide superior protection in applications where cables and wires must pass through barriers while maintaining environmental sealing integrity. We specialize in LSR (Liquid Silicone Rubber) and HCR (High Consistency Rubber) silicone wire seals with self-lubricating properties for automated harness assembly.
Our wire seals feature precise dimensional control, ensuring perfect fit and reliable sealing performance. Most of our SWS designs utilize a three-lip (triple lip) configuration creating three layers of redundant sealing for superior IP67/IP68 protection. We offer both standard catalog items and custom-designed solutions to meet specific application requirements. Our engineering team works closely with customers to develop wire seals that address unique challenges such as multi-wire configurations, high-temperature environments, and chemical exposure.
With advanced manufacturing capabilities including LSR injection molding, compression molding, and multi-shot molding, we can produce wire seals in various configurations including single-wire seals (SWS), multi-wire seals, cavity plugs (dummy plugs/blind plugs), peripheral seals, and transition seals. Our self-lubricating LSR wire seals are harness automation ready, designed for high-speed automated crimping and insertion processes. All products meet international standards including IP67/IP68 protection ratings and are compliant with automotive specifications such as USCAR and SAE standards.
Quality is paramount in our manufacturing process. Each wire seal undergoes rigorous testing including leak testing, pull-out force testing, and environmental cycling to ensure consistent performance. Our ISO 9001:2015 certified facility utilizes state-of-the-art inspection equipment to maintain the highest quality standards throughout production.
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Frequently Asked Questions
Find answers to common questions about wire seals, single wire seals (SWS), and cavity plugs
Wire seals, also known as gum seals or cable seals, are precision-molded rubber components that seal individual wires as they pass through automotive connectors and electrical housings. They provide IP67/IP68 waterproof protection, preventing moisture, dust, oil, and contaminants from entering the connector cavity and causing electrical failures.
ARPL manufactures wire seals from automotive-grade materials including Silicone (VMQ), EPDM, HNBR, FKM (Viton®), NBR, Neoprene, and TPE. Material selection depends on temperature requirements (-60°C to +200°C), chemical exposure, flexibility needs, and specific environmental conditions of the application.
ARPL wire seals accommodate wire diameters ranging from 0.5mm to 50mm. We offer standard sizes for common wire gauges as well as custom-designed seals for specific wire harness configurations. Our engineering team can develop seals for multi-wire applications with varying conductor sizes.
Yes, ARPL wire seals are extensively used in electric vehicle applications including high-voltage battery connectors, BMS (Battery Management System) wiring, motor controller interfaces, charging port connections, and DC-DC converter harnesses. Our silicone and FKM seals meet the demanding temperature and chemical resistance requirements of EV powertrains.
ARPL wire seals are designed to achieve IP67 and IP68 protection ratings when properly installed. IP67 provides complete dust protection and water immersion resistance up to 1 meter for 30 minutes. IP68 offers continuous water immersion protection at greater depths, depending on the specific seal design and connector housing configuration.
Yes, ARPL exports wire seals and gum seals to major automotive markets worldwide including USA, Germany, Mexico, Thailand, Vietnam, Turkey, UAE, and Brazil. All products are manufactured with REACH and RoHS compliance for international export. Our logistics team ensures proper documentation and timely delivery to global customers.
Absolutely. ARPL provides full custom tooling support for application-specific wire seal designs. Our engineering team works with customers from concept through production, offering design assistance, material recommendations, prototyping, and high-volume manufacturing. We can develop seals for unique connector interfaces, special wire configurations, and demanding environmental requirements.
ARPL is ISO 9001:2015 and IATF 16949:2016 certified with a zero-defect manufacturing approach using cryogenic deflashing for burr-free seals. All wire seals are REACH and RoHS compliant. Our quality control includes dimensional inspection, leak testing, pull-out force testing, and environmental cycling to ensure consistent performance and reliability.
A Single Wire Seal (SWS) is a rubber sealing element with three interfaces: wire, contact, and cavity. The SWS is crimped onto the contact terminal and inserted into the connector cavity. Most SWS designs use a three-lip (triple lip) configuration creating three layers of redundant sealing for superior IP67/IP68 protection against moisture, dust, and contaminants.
LSR (Liquid Silicone Rubber) wire seals are manufactured using injection molding with liquid two-component silicone, offering excellent precision and consistency for high-volume production. HCR (High Consistency Rubber) silicone is processed through compression or transfer molding. LSR is preferred for automated harness assembly due to its self-lubricating properties and faster cycle times.
Yes, ARPL manufactures self-lubricating LSR wire seals specifically designed for automated wire harness assembly. The built-in lubrication (typically 1-5% oil content) reduces insertion force, prevents seal damage during crimping, and ensures smooth passage through automated equipment. These harness automation ready seals are available in 40-60 Shore A hardness.
Cavity plugs (also called dummy plugs or blind plugs) are used to seal unused connector cavities where no wire or contact is present. They maintain the IP67/IP68 seal integrity of the connector housing by blocking empty positions. ARPL manufactures cavity plugs in the same materials as our wire seals - LSR, HCR silicone, EPDM, and FKM - for complete connector sealing solutions.