O-Ring Groove Design Guide | Squeeze & Extrusion Safety

Practical groove depth/width/tolerance guidance with squeeze and extrusion safety notes for static and dynamic seals.

Key targets

  • Static squeeze 15–25%
  • Dynamic squeeze 10–20%
  • Surface finish 8–32 μin Ra
  • Extrusion gap control with backup rings

Design steps

  • Pick cross-section and squeeze by application (static/dynamic/high pressure).
  • Set groove depth/width to hit squeeze and fill ratio.
  • Control chamfer and surface finish to avoid cuts.
  • Use PTFE backups when pressure/clearance risk extrusion.

Common pitfalls

  • Over-squeeze → compression set
  • Too little squeeze → leakage
  • Rough surface/chamfer burrs → nicks
  • No backup at high ΔP → extrusion