By Dongyeop Shin (Jan 2025)

As a trusted global provider of advanced sealing and wear technologies, Omniseal Solutions specializes in custom-engineered polymer and metal seals for the most demanding applications, integral to critical systems in aviation, space, energy, and life sciences, where reliability and precision are paramount.

In the aviation industry, our business supports hybrid-electric engine technology by providing high-performance Omniseal® rotary lip seals for generators. Made from advanced polymer materials, these sealing solutions offer lifetime protection for bearings, preventing oil leaks at variable speeds, which is critical for reliable, low-maintenance performance. We also develop tailor-made sealing solutions to solve unique challenges in hydrogen environments. In hybrid-electric engines and hydrogen fuel systems, extreme temperatures, pressures, and aggressive media can be difficult to manage. Customers require safety, efficiency, and reliability in hydrogen fuel pumps and within the hydrogen value chain. Our innovative sealing solutions ensure optimal performance and durability. 

• Omniseal® Spring-Energized Seals: These precision seals combine a high-performance polymer jacket with a corrosion-resistant metal spring to deliver consistent performance in extreme environments, such as cryogenic temperatures and high-pressure conditions. They are especially suited for hydrogen storage and aerospace applications.

• Omniseal® Rotary Lip Seals: Engineered with durable polymers and metal casings, these seals excel under extreme temperatures, high speeds, and exposure to aggressive chemicals, making them ideal for hybrid-electric engine components.

• Omniseal® Metal Seals: Designed to endure extreme pressure and temperature fluctuations, these high-performance seals offer exceptional reliability and flexibility for demanding systems, including those found in hydrogen-fueled applications.

By partnering with engineers for many years, we have been able to go beyond together to drive progression in aviation; i.e., advanced air mobility. The following are several key industry insights about the challenges and future of electric aircraft.

What are some of the most significant challenges facing the aviation industry when developing hybrid-electric engines? How is Omniseal Solutions addressing these challenges?

The development of hybrid-electric engines within aviation markets presents several challenges, including optimizing power density, high-speed performance, and fuel flexibility. Achieving high efficiency in a compact design requires components such as high-speed rotating shafts (operating at speeds exceeding 11,500 RPM or 44 m/s) that connect the turbine to the power converter. These generator shafts must perform reliably across variable speeds while maintaining low leakage rates throughout the full-speed range. Additionally, seals must be durable enough to last the engine's lifetime, reducing engine downtime and minimizing maintenance needs.

Could you explain the importance of sealing technology in enhancing engine performance and efficiency?

Precision sealing technology such as Omniseal® rotary lip seals are designed with a flexible inner lip that adapts to the shaft’s surface, creating a gas-tight seal that supports proper lubrication and keeps out contaminants. This feature is essential for the reliability and longevity of hybrid-electric engines, which often operate under challenging conditions, including high speeds and varying temperatures. Made from proprietary materials, these
seals are capable of withstanding demanding environments. In addition to meeting the previously discussed requirements, these seals improve engine durability, which is critical as the aviation industry moves toward cleaner and more efficient propulsion systems. Sealing technology has evolved significantly from the initial development of polymer lip seals to prolong the service life of bearings and rotating shafts, i.e., basic leather washers to advanced materials like polytetrafluoroethylene (PTFE). 

• Want to know more about the design and function of rotary lip seals? Read our blog post, "What is a Rotary Lip Seal?"

How do Omniseal Solutions’ sealing technologies contribute to a more sustainable future in aviation, particularly in hybrid-electric and hydrogen-fueled engines?

Omniseal Solutions is advancing sustainable aviation through innovative sealing technologies that address critical challenges in emerging propulsion systems. Our engineered seals for hybrid-electric engines optimize performance by reducing weight and space requirements, improving fuel efficiency and enabling more compact, environmentally-friendly designs.

In hydrogen-powered applications, particularly fuel pumps, we developed proprietary seal materials that maintain exceptional wear resistance and dimensional stability under extreme conditions. This ensures safe and reliable hydrogen transport across challenging operational environments. Moreover, our research focuses on two primary sustainability objectives: material innovation and performance optimization. We are developing PFAS-Free* sealing materials that extend durability and maintenance intervals while meeting stringent environmental regulations. 

• Take a closer look at our PFAS-Free* case studies: semiconductor hot melt dispensing equipment and life science UHPLC piston pump.

Simultaneously, we are implementing advanced simulation tools and comprehensive material testing to minimize system emissions and improve overall seal design. By continuously refining our sealing technologies, we are not just supporting sustainable aviation - we are engineering the solutions that will define next-generation aerospace propulsion systems.

* PFAS-Free here means we do not intentionally add PFAS material in the product, but does not exclude the possibility of traces, as these materials are common in the environment.

Would you like to hear more industry insights from our aviation experts? Click the above PRINT button for our full Q&A technical article!