How to Achieve IP67/IP68 Seals in Plastic Enclosures (Without Gaskets)
Short Answer
RF welding is one of the most effective methods for achieving IP67/IP68 sealing in plastic enclosures without gaskets. Among these methods, Emabond RF welding enables a continuous, hermetic-style seal path without relying on compression, fasteners, or adhesives, making it well suited for complex geometries and long-term sealing performance.
Key Takeaways
- RF welding enables IP67/IP68 sealing without gaskets or adhesives
- Emabond RF welding creates a continuous internal seal path for long-term reliability
- Gaskets introduce variability due to compression, torque, and aging
- Ultrasonic and laser welding are effective but limited by geometry, size, and materials
- The best sealing method depends on geometry, materials, and performance requirements
Common Methods for IP67/IP68 Sealing
Quick comparison of sealing methods:
- Gaskets + screws – serviceable but dependent on compression and hardware consistency
- Ultrasonic welding – fast but limited by geometry, material, and joint design
- Laser welding – clean but requires material compatibility and line-of-sight
- RF welding – enables continuous internal seal paths without gaskets
- Emabond RF welding – extends RF welding capabilities to complex geometries, engineered materials, and dissimilar thermoplasics
Ultrasonic welding is fast but can be limited by geometry and joint design. See a full comparison in Ultrasonic vs RF Welding for Sealed Enclosures.
Why Traditional Methods Fail in IP67/IP68 Applications
- Depend on compression, not a permanent bond
- Sensitive to torque variation
- Affected by thermal cycling and material creep
- Require flat, consistent mating surfaces
- Degrade over time
Many of these issues stem from the limitations of compression-based sealing. For a deeper breakdown, see Why Gaskets Fail in IP67/IP68 Applications.
Best Method for Hermetic-Style Gasket-Free Sealing
The best method is one that creates a continuous, repeatable seal path aligned with the enclosure geometry and materials. In many applications, RF welding provides this capability, with Emabond RF welding offering additional flexibility for more demanding designs.
For a deeper breakdown of sealing approaches and how different methods compare, see Best Method for Hermetic Seals in Plastic Enclosures.
How RF Welding and Emabond Solve These Challenges
- RF welding creates a continuous internal seal path instead of relying on compression
- Emabond RF welding eliminates the need for screws, gaskets, and adhesives
- RF welding supports more consistent sealing across production
- Emabond RF welding enables complex geometries and hidden joint designs
- Emabond RF welding supports dissimilar material welding applications
Applications
- Sensor housings and industrial electronics
- Outdoor control modules and enclosures
- Fluid-handling components such as pumps, valves, and blower housings
- Battery, power, and mobility enclosures
- Medical and diagnostic housings
Conclusion
RF welding is one of the most effective approaches for achieving IP67/IP68 sealing in plastic enclosures without gaskets. Emabond RF welding builds on this by enabling a continuous internal seal path that improves long-term reliability and reduces dependence on mechanical compression, making it a strong solution for modern plastic enclosure sealing challenges.