AVIATION

Advanced Air
Mobility (AAM)
Handbook

ENGINEERING
THE WORLD OFTOMORROW
Precision Sealing &Advanced Material
SolutionsA KEY PARTNER & COLLABORATORIN THE AVIATION INDUSTRY

Omniseal Solutions is a global engineering leader with over 65 years ofhistorical legacy, relentlessly dedicated to the design and manufactureof precision sealing and wear control solutions that protect criticalapplications in the most demanding environments and passionately
driven to push “Beyond the Boundaries of Possible”.
AAM BENEFITS: SAFE, QUIET, GREEN & ECONOMICALThis collaborative spirit has led us
to be specialists in engineeringand manufacturing many
precision sealing and advanced
material solutions for rapidly
evolving markets such as Electric
Vertical Take-off and Landing(eVTOL) aircraft, which are poised
to revolutionize the world ofaviation and our future mobility.
How does Advanced Air Mobility(AAM) affect our daily lives andcommunities? From urban
air transport to logistics andemergency medical services,
they are proving to support
sustainability, mobility, time
efficiency, accessibility, andconnectivity.

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Reduced need for vehicle
traffic within urban core

Increased range ofaccess to the urban core

Increased utility of airport
infrastructure

Additional transportation
options (social equity)

Integration withexisting commutertransit and roads

Safe mode oftransportation withlow emissions

FUTURE TECHNOLOGYFOR US ALL

TECHNOLOGY ADVANTAGESTHAT TAKE YOU FARTHERA WEIGHT OFF YOUR SHOULDERS
One of the most persistent and challenging issues in advanced
air mobility and eVTOL design is meeting stringent weightrequirements – a requirement well known in aircraft manufacturing– but not as simple to solve.
Since the genesis of aviation, technical teams have explored novel
space and weight-saving solutions, promising cross-compatibility
with emerging technologies. Aircraft sealing and material solutions
are one example that are enabling the reliable and safe operation of
key advanced air mobility systems. Omniseal Solutions has worked
closely with customers to customize solutions to handle existing
and future high-performance requirements, moving them ahead asindustry leaders.
A HANDLE ON HIGH PRESSURE & HIGH TEMPERATURE
To solve high pressure and high temperature (HPHT) stringent
requirements, our jet engine and gas turbine seals provide tight andconsistent sealing control capable of withstanding high pressuresand temperatures, ensuring optimal performance in extreme
operating conditions. Our Omniseal® spring-energized seals andmetal seals, in particular, have proven to be invaluable, whereconventional seals might fail due to the demanding environment.
A CUSTOMIZATION THAT COUNTS
Our polymer jacket and spring material or metal ring with coating
are customized for precision, including the ability to adjust springloads as required. These unique designs and materials provide
outstanding thermochemical compatibility and high-speed
dynamics. These are all critical criteria when it comes to pushing theperformance boundaries of advanced air mobility systems.
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Global Capabilities & Services

A WORLD PARTNER OF ENGINEERING& MANUFACTURING EXPERTS
How does our business add value andimpact to your missions and goals? Oneof our strengths is our global history andlongevity in the aviation industry, having
provided over millions of polymer seals,
metal seals, polyimides, thermoplastics,
composites and polymer materials forapplications in commercial and military
aircraft; helicopters; eVTOLs, and hybrid
electric vehicles.
A global presence with 17 manufacturing
plants, 8 R&D transversal centers andtechnical teams with many years ofexperience, we can provide global reachas well as local support with top industrial
standards such as AS9100D.

Design Support
Our relentlessly dedicated engineers problem
solve and collaborate to create custom solutions
for lifetime confidence.
Simulation
With simulation services, we help customers
understand how a prototype will react in working
conditions and its impact in the world.
Assembly
From molding to assembly, our operating teams
have the machines and knowledge to deliverconsistent and high quality parts.
Installation Tools
To prepare for success, our technical teamprovides detailed video and written installation
guides. We also design specific tools based on
expertise of application performance.
Fast Sample Delivery
Time is critical so if you need a sample quickly, you
can depend on our rapid response and delivery
along with follow up technical advice.
Rapid Prototyping
Since your application may be new or indevelopment, you can request a custom designed
prototype that is delivered at your premises when
you need it.
In-House Testing
From analysis of raw materials to testing samples
and verification, our R&D and technical teams
support all validation processes.

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Solving Your Challenges

CREATIVE, UNIQUE, PROVEN & CUSTOM ENGINEERING
What is Omniseal Solutions known for? We protect critical systems with custom
material formulations and precision designs. From polymer powders to complex
assemblies, our solutions are designed to handle extreme environments.

CREATIVE MATERIALSCUSTOM DESIGN• Materials and formulations thatare developed for an extensive
range of applications•P ermanent development andvalidation of new solution
designs• Broad temperature / pressure
range• Pre-validation testing• Wide chemical compatibility• Certification for extreme
conditions•C o-development withcustomers for optimum
performance

UNIQUE SIMULATIONEXPERTISE

PROVEN PROCESS EXPERTISE• Simulation tools development• Compression molding• Test-based material models• Simulation engineering
services• Injection molding• Machining• Stamping• Direct Forming• Skiving

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PROTECTING YOUR CRITICAL SYSTEMSPROPELLER & TRANSMISSION SYSTEMS
Environmental Shaft Seals
Gearboxes
Rotorhead Seals
Electric Propulsion Unit (EPU)

FLIGHT CONTROL SYSTEMS
Primary Control Actuators
Secondary Control Actuators

CREATING PRECISION SEALING SOLUTIONS TOGETHER
Aviation customers have trusted our business for decades to protect their systems, using ourcustom sealing components that solve many application challenges such as aggressive media,
high temperature, high pressure, high speed, and leakage rate. With our diverse portfolio of
proven solutions, our sealing knowledge and experience have grown with our customers so they
can go beyond in present and future technologies. Together, we partner to engineer the world of
tomorrow efficiently, safely, and with confidence.

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Omniseal® Spring-Energized Seals

Omniseal® Metal & Boss Seals

Omniseal® Rotary Lip Seals• Temperature range: -254 to 365°C• Temperature range: -269 to 1150°C• Temperature range: -55 to 230°C• UHV to 15,000 psi (1035 bar)

• Leak Rates: < 10• Low friction and wear in dry abrasive media• Broad chemical compatibility• Vacuum to 100,000 psi (6894 bar)

• 3mm to 6m size

• All fluids and gases-10

cc/sec• High speed rotary applications

Our polymer and metal solutions are used in many
critical systems for sealing, wear, and friction control.

ENVIRONMENTAL CONTROL SYSTEMS (ECS)HVAC Systems
Cabin Pressure Systems

APU & HYBRID POWER SYSTEMS
Gearboxes
PTO Components
Cryo, Vacuum & Liquid Hydrogen Seals
Motor Shaft Lip Seals
Electric Propulsion Unit (EPU)

POWER ELECTRONIC SYSTEMSPower Converters
Electric Systems
Vacuum Rotary Shaft Seals for Superconductivity

SENSING SYSTEMS
Optronics
Angle of Attack
Sensors

CREATING ADVANCED MATERIAL SOLUTIONS TOGETHER
Formulating unique and advanced materials is one of the technology advantages we are known
for in the aviation industry. Since aviation is a fast growing market, requirements and regulations
are changing at the same rapid pace. By working closely together with you and understanding
your present and future needs, we can create material solutions that ensure reliability, provide highperformance and manage extreme conditions. Our materials can “weather” any challenge you face.
RULON® FLUOROPOLYMERSHYCOMP™ COMPOSITES• Temperature range: -250°C to 288°C• Carbon/Glass fiber re-enforced• Broad chemical compatibility• Very high mechanical strength• Low deformation under load

• Temperature up to 315°C• Self-lubrication• High stiffness & lightweight• > 1000 formulations

MELDIN® HT THERMOPLASTICSMELDIN® POLYIMIDES• Engineered Thermoplastic• Temperature range: -250°C to 320°C• Temperature range: -250°C to 280°C• High strength at high temperatures• All volume coverage• Wear resistance under high load

• IT6 tolerance control, 0 ppm inMillion part volume• High thermal-oxidative stability

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POWER ELECTRONIC SYSTEMSPower Converters
Electric Systems
Vacuum Rotary Shaft Seals for Superconductivity

IBG

Omniseal® Spring-Energized Seal

Versatile

Close to increasing
highest temperaturesin the engine, HTS
oil is mandatory,elastomer-based
seals are ruled out

High spring load with small deflection

Like-to-like groove fit for
O-Ring replacement

Extremely low leak rate
High performance polymer inert to all
known standard oils
A90 material available for high temps
Based seals are ruled out

Lifetime performancesuperior to elastomer seals
Lower cost & weight forlarger diameters

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers

Solution
Omniseal® Spring-Energized
103A Seal

Internal
Gearbox Seal

High performance A08, A10, A21 andA90 polymer materials are preferredSpecifications
Nominal ID of seals between 0.25"
and 6" (6.35 to 150mm)
Seal can be installed in closed or
reduced gland
Low pressures

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USE CASE

Typical Temperature:-55 to 350°C (-65 to 665°F)
Media
Compatible with air and aerospace
oils

POWER ELECTRONIC SYSTEMSPower Converters
Electric Systems
Vacuum Rotary Shaft Seals for Superconductivity

Generator in
Hybrid Engine
Generator shaft rotates
at variable speeds, up tohigh surface speeds. Hightightness on complete
speed range required.

Omniseal® Rotary Lip Seal

Extended Operations

Omniseal® rotary lip seal has anextremely tough, long wearing
jacket material and a good
resistance to wear

Long seal life minimizes
down time
PTFE lip seals able to run dry
in case of loss of lubrication

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers
Hybrid Engine
Generator Seal

Solution
Omniseal® Rotary Lip Seal

Typical Temperature:-40°F to 302°F (-40°C to 150°C)

Specifications
Dynamic sealing between seal androtating shaft

RotationHigh speed rotary capabilities, up to
11.500 RPM (44 m/s)

Static sealing between seal andhousing​Media
Compatible with aerospace fluids: oil

Very low leakage, with seal lasting
entire lifetime
Lip seal low friction leading to
reduced energy consumption

USE CASE

9POWER ELECTRONIC SYSTEMSPower Converters
Electric Systems
Vacuum Rotary Shaft Seals forSuperconductivity

Harsh Conditions

Omniseal® Rotary Lip Seal

Extended Operations

Possible dirt, dust andabrasive particles

Omniseal® rotary lip seal has anextremely tough, long wearing
jacket material and a good
resistance to wear

Long seal life reduces
downtime

Different running conditions:switches between dry
periods, wet environment,abrasive environment

In case of loss of lubrication,
seals are still able to run dry

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers
Electric Motor
Environmental
Seals (bearing
protection)

Solution
Omniseal® Rotary Lip Seal

Typical Temperature-60°F to 250°F (-51°C to 120°C)

Specifications
No allowable leakage

Rotation
up to 12.000 RPM, surface speed up
to 40 ft/s (12 m/s)

35.000 hours lifetime required
Low pressure, only slightdifferential pressure due totemperature differences
Lip seal low friction leading to
reduced energy consumption

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USE CASE

Media
Compatible with environment (saltspray, rain, de-icing agents, sand,dirt, dry, …)

FLIGHT CONTROL SYSTEMS
Primary Control Actuators
Secondary Control Actuators

Electromechanical
Actuation
Low friction solution forreciprocating movement
Compatible with aerospace
fluids like hydraulic oils,
de-icing fluids, fuels

Omniseal® Spring-Energized Seal

Easy Installation

Low sensitivity to thermal aging ofpolymer material on the Omniseal®
jacket provides better sealing
control and lifetime confidence

Seals can be designed forexisting glands

Seals can be custom designed tomeet low friction requirements

Seals can be installed into
closed and reduced glands

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers
Electromechanical
Actuation Seal

Solution
Omniseal® Spring-Energized Seal
Specifications
Low friction seals for reciprocating
movement
Provides static sealing between seal
and housing
Provides dynamic sealing between
seal and moving shaft

Typical Temperature
Temperature range from -50°C up to
150°C (-60°F up to 300°F)
Typical Movement
Reciprocating movement with aspeed of 0.01 m/s (2 ft/min)Media
Hydraulic oil, de-icing fluids, cleaning
fluids, oils (including HTS grades),fuels

USE CASE

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FLIGHT CONTROL SYSTEMS
Primary Control Actuators
Secondary Control Actuators

Engine Actuation

Meldin® Polyimide

Lower Weight & Durability

Metal casing provides tight control
and wear protection since the partis submitted to friction & wearfrom vibration and sliding motions,immersed in jet fuelMeldin® Polyimide parts have excellent
mechanical performance with a goodcompromise between the wear resistance, its
creep resistance & its coefficient of friction

Carbon filled polymers are lighter
than metals, reducing weightand combining wear and friction
resistance qualities

Compatible with aviation fuels

Self lubrication increases durability
and lowers coefficient of friction

Relatively High temperature arereached up in the actuators

Self lubrication allows low sulfur fuel grades,
like SAF

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Meldin®
Polyimides
Fuel Driven
Actuators &Fuel Control
Valve Bushings& Split Rings
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USE CASE

Solution
Meldin® 7500 Bearing

Typical Temperature
Up to 135°C (280°F) or higher

Specifications
Structural part for shaft guiding,high creep resistanceMedia
Aerospace grade fuels

Low friction & wear
Compatible with fuel immersion
Tight tolerances

ENVIRONMENTAL CONTROL SYSTEMS (ECS)HVAC Systems
Cabin Pressure Systems

Environmental Control
Systems
ECS are complex withmultiple suppliers andmany metal parts

Glass Filled PEI

Valve Body Housing

Potential weight savings of 40%
over aluminum and 75% overstainless steel and titanium due tolower density of composite

Using complex injection
molding with integrated
finish machining andbonded aluminum sleeve
assembly, enables areduced complexity andweight savings

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Meldin®
Polyimides
Valve Body
Housing Injection
Molded Parts

Solution
Meldin® 3200 Injection Molded Part

Typical Temperature
Up to 150˚C (300˚F)

Specifications
Couples inlet to outlet sections of thesystem, and houses butterfly platefor pressure control

Media
Hot Air

Hybrid design for burst pressure
consideration

USE CASE

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ENVIRONMENTAL CONTROL SYSTEMS (ECS)HVAC Systems
Cabin Pressure Systems

Hot Air Valve

Omniseal® Spring-Energized Seal

High temperatureapplication

Excellent for static or dynamic
sealing, with extremely low leakrate and long lifetime

Accommodation of thermal
dilatation and strain

Low Weight& Flexible Design
Seal can be installed in
multiple applications,
without changing thedesignLow sensitivity to thermal aging ofpolymer material

Lower cost & weight forlarger diameters

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

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Omniseal®
Polymers

Solution
Omniseal® Spring-Energized
103A & 400A Seals

Air Management
Bleed Air ValveSeals

A08 & A10 are preferred materials

USE CASE

Static, Reciprocating & Rotary Seals
Specifications
Nominal ID of seals between 0.25”
and 10” (6 To 254 mm)

Typical Temperature-54 to 288°C (-65 to 550°F)
Typical Pressure
7 PSI to 85 PSI (0.5 to 6 bars)Media
Hot Air

ENVIRONMENTAL CONTROL SYSTEMS (ECS)HVAC Systems
Cabin Pressure Systems

Customer Challenge
High air temperature
sealing solution withstrong thermal resistanceto deliver the heat only
at expected places withminimal losses

Meldin® Polyimide& Omniseal® Flat Gasket
Meldin polyimides & highperformance polymers are able tosustain bleed air temperatures®

Assembly with Omniseal® seal
replaces 2 different components foreasier integration

Comfort and Safety
The combination of Meldin®
polyimides (thermal insulation)& Omniseal® seals (excellent
sealing) enable low heat loss
for efficient de-icing

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Meldin®
Polyimides

Solution
Meldin® 7001 Polyimide& Omniseal® Flat Gasket

Wing Deicing
Duct Sealing
Gaskets

Specifications
Heat transfer from bleed air tube towing structure not allowed

Thermal Properties
Excellent thermal insulative
properties & low thermal
conductivity

Structural integrity required atelevated temperatures
Excellent ductility for long life

USE CASE

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SENSING SYSTEMS
Optronics
Angle of Attack
Sensors

Sensor Seal

Omniseal® SRII

Polymer Materials

More tightly controlled
and consistent friction
while also having no
stiction give largeadvantage overelastomer seals

Multiple energizers can be usedin larger glands to fit into existing
hardware without sacrificing
precision fit

Self-lubricating anti-wear
properties of recommended
Fluoroloy® materials of theOmniseal® jacket allow dry
installation and operationand superior lifetime

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers

Solution
Omniseal® Spring-Energized
SRII Seal

Equipment Angleof Attack Sensor
Seals

A42 and A49 are preferred materials
Specifications
Nominal ID of seals between 0.1"
and 1" (2.54 to 25.4 mm)
Pressure from 1 PSI to 13 PSI(0.1 to 0.9 BAR)
Rotary Seal16

USE CASE

Typical Temperature-54 to 85°C (-65 to 185°F)
Media
Air, Dust, Moisture, De-Icing Solution

SENSING SYSTEMS
Optronics
Angle of Attack
Sensors

Sensor Gimbal

Omniseal® Spring-Energized Seal

High Reliability

A more tightly controlled andconsistent friction, while also
having no stiction, provides
a major advantage overelastomer seals

Self-lubricating anti-wear propertiesof recommended Fluoroloy®
materials of the Omniseal® jacket
allow dry installation and higher
lifetime confidence

Like to like groove fit for O-ring
replacement
Leakage and friction testingavailable

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers

Solution
Omniseal® Spring-Energized APS& 400A Seals

Equipment
SensorGimbal Seals

Specifications
Nominal ID of seals between 2 and10" (50 to 250 mm)

Typical Temperature-55 to 80°C (-65 to 180°F)
Media
Compatible with environmental air,dirt, dust, water

A01, A15 and A49 are preferredmaterials used
Low, tightly controlled friction
Pressure 3 to 20 PSI (0.21 to 1.38 BAR)USE CASE

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PROPELLER &TRANSMISSION SYSTEMS
Environmental Shaft Seals
Gearboxes
Rotorhead Seals
Electric Propulsion Unit (EPU)

Harsh Conditions

Omniseal® Spring-Energized Seal

Improved Reliability

Possible dirt, dust andabrasive particles

No stick-slip effectImproved sealing of grease

Lower coefficient of friction

Seals able to run dry in caseof loss of lubrication

Critical part (Rotorhead)Long life time

Compatible with any aerospace fluid
No leakage

Immediate capability of
dampers

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers

Solution
Omniseal® Spring-Energized
103A Seal

Helicopter
Rotorhead Amper
Seals

Specifications
Dynamic sealing between seal andsliding shaft
Static sealing between seal andhousing
Very low leakage
Pressure up to 2000 PSI (140 BAR)18

USE CASE

Typical Temperature-65F to 160°F (-54°C to 71°C)
Media
Compatible with aerospace fluids(for instance glycol)

PROPELLER &TRANSMISSION SYSTEMS
Environmental Shaft Seals
Gearboxes
Rotorhead Seals
Electric Propulsion Unit (EPU)

Harsh Conditions

Omniseal® Rotary Lip Seal

Extended Operations

Possible dirt, dust, andbearing particles in oil

Omniseal® rotary lip seal has anextremely tough, long wearing
jacket material and a good
resistance to wear

Long seal life reduces downtime

Possible loss of lubrication
Eccentric sealing conditions

Seals able to run dry in case ofloss of lubrication

High load overhung loads
Wide temperature extremes

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers
Helicopter Vertical& Horizontal Hinge
Pin Seals

Solution
Omniseal® Rotary Lip Seal

Typical Temperature-60F to 200°F (-51°C to 90°C)

Specifications
Dynamic sealing between seal androtating shaft

RotationHigh speed rotary capabilities

Static sealing between seal andhousingMedia
Compatible with aerospace fluids

Lateral movement support required
No allowable leakage
1000 hours lifetime required
Pressure 14 to 35 PSI (1 to 2.4 BAR)USE CASE

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PROPELLER &TRANSMISSION SYSTEMSAPU & HYBRID
POWER SYSTEMS

Environmental Shaft Seals
Gearboxes
Rotorhead Seals
Electric Propulsion Unit (EPU)

Gearboxes
PTO Components
Cryo, Vacuum & Liquid Hydrogen Seals
Motor Shaft Lip Seals
Electric Propulsion Unit (EPU)

Minimum Energy
Consumption

Omniseal® Rotary Lip Seal

Extended Operations

In dynamic and static conditions,this rotary lip seal offers leak tightprotection over a long lifetime, while
reducing frictional torque to theminimum

Longer maintenance cycle
reduces operation cost

Minimal frictional torquereduces energy usage

The compact and efficient design
saves space and weight

PROVEN SUCCESS IN CRITICAL SYSTEMS & APPLICATIONS

Omniseal®
Polymers
Electric Propulsion
Unit (EPU) Seals

Solution
Omniseal® Rotary Lip Seal
Specifications
Pressure 0 to 1 PSID
Minimum to no leakage
Lifetime: 20,000 to 35,000 hours
Lip seal low friction leading to
reduced energy consumption

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USE CASE

Typical Temperature-40F to 300°F with proprietary
Fluoroloy® material
Rotation
up to 12.000 RPM, surface speed up
to 100 ft/s (30 m/s)
Media
Compatible with aircraft turbine
engine lubricating oil such as MILPRF-7808 & MIL-PRF-23699

MAKE A CONNECTION TODAY
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Scan the below QR codes, or view our world map to contact one of your local experts!

INDUSTRY & SOLUTION HANDBOOKSSOCIAL MEDIA & TECHNICAL CENTER

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ONE GLOBAL TEAM… A DEDICATED CUSTOMER FOCUS

AS9100D
Aviation
Certification

GLOBAL & LOCAL PRESENCE
With 17 manufacturing facilities in 10 different countries, Omniseal Solutions is a diverse group thatis committed to being customer centric.
Contact our team of experts for more information. We have local resources to support you!
· Americas: Garden Grove, CA, USA; Bristol, RI, USA; Orange, CT, USA; Cleveland, OH, USA; Northboro, MA; Saltillo, MX· Europe: Kontich, Belgium; Vimercate, Italy; La Rioja, Spain; Kolo, Poland; Willich, Germany· Asia: Shanghai, China; Bangalore & Chennai, India; Suwa & Tokyo, Japan; Seoul & Incheon, South Korea; Taipei, Taiwan

help@omniseal-solutions.com
www.omniseal-solutions.com
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