Engineering Precision Sealing for the Next Generation of Electric Aircraft

Overview

This interview with Dongyeop Shin, Aerospace Sales Manager at Omniseal Solutions, highlights the critical role of precision sealing solutions in advancing electric propulsion systems for next-generation urban air mobility (UAM) and electric aircraft. As the aerospace industry shifts toward sustainable and high-performance flight, sealing technologies must adapt to unique challenges posed by electric propulsion units.

Electric motors in these aircraft operate at high speeds, high voltages, and compact scales, demanding seals that can withstand thermal fluctuations, mechanical loads, and exposure to new dielectric coolants. Reliability is paramount due to the safety-critical nature of UAM vehicles, requiring seals that prevent leakage while minimizing friction and wear to ensure extended service life and low maintenance.

Omniseal Solutions leverages advanced materials such as polymer-based composites and polyimides, which offer a balance of thermal resistance, electrical insulation, and dimensional stability under extreme conditions. For example, polyimide materials maintain strength at continuous temperatures above 300 °C and provide dielectric protection essential in high-voltage environments. Thermoplastics and fiber-reinforced composites are also used extensively in auxiliary power units and flight control actuators, providing resistance to combined thermal, mechanical, and chemical stresses while reducing weight by approximately 40% compared to metals—an essential factor for efficiency in UAM aircraft.

The reliability of seals in high-speed rotating parts like motors and gearboxes depends heavily on material properties and precise engineering. Low-friction, wear-resistant polymers are optimized through lip geometry and contact pressure adjustments to create stable barriers that retain lubricants and exclude contaminants, reducing friction and wear and thereby extending component life in tight, vibration-prone spaces.

Thermal runaway and electromagnetic interference risks are significant in electric aircraft, given the presence of compact high-voltage motors and electronics. Omniseal’s Meldin® polyimide materials act as thermal barriers to keep components cool under extreme temperatures up to 316 °C, while Hycomp™ composites provide critical electrical insulation to prevent arcing or short circuits in closely packed assemblies, contributing also to overall weight reduction and corrosion resistance.

Finally, Omniseal employs advanced numerical simulations alongside rigorous in-house and external testing to validate sealing designs against real-world conditions, such as thermal cycling and pressure differentials at altitude. This integrated approach enables optimization and de-risking of seals to maintain integrity and safety throughout the operating envelopes of electric vertical takeoff and landing (eVTOL) and electric aircraft.

For more information, visit www.omniseal-solutions.com.