We test the part in simulation first.
In our R&D centre, approved in September 2025, material, geometry and tooling are designed together.
The geometry of a dust cover is derived from the motion envelope of the shaft it seals and the environment it works in.
Design starts from the degrees of freedom in the OEM specification and the environmental conditions of ISO 16750. Through the tie-rod shaft’s tilt and twist of ±20° to ±35°, the part is dimensioned to run clear of every component around it.
Material behaviour is simulated in finite element analysis with Mooney-Rivlin and Ogden hyperelastic models. Convolution wall thickness and corner radii are optimised so that the stress of dynamic folding spreads evenly through the body.
Compound formulations are designed in-house to the customer’s requirements and specifications, mixed in laboratory-scale open and closed mixers, and approved for the first series against the tests the specification sets.
Technical summary
- Simulation
- FEA; Mooney-Rivlin and Ogden hyperelastic models
- References
- OEM specifications, ISO 16750 environmental conditions
- Motion envelope
- ±20° to ±35° tilt and twist
- Approval
- First-series approval at laboratory scale
Our design solutions
Durability is drawn in.
What failure analysis teaches us goes into the geometry of the next part.
- Stress distribution
- Wall thickness and convolution radii are optimised in simulation, so stress spreads evenly through the body.
- Double-lip sealing
- Contact pressure holds through the shaft’s axial and angular movement, and the grease film stays inside.
- Static sealing
- A clamp groove and sealing profile fill the micro-gaps on the housing and keep water and mud outside.
- Parting line
- The mould’s parting line sits away from every critical sealing surface.
- Polymer choice
- CR and TPU matrices that stay stable in grease and flexible from −40 °C to +120 °C.
Direct line
Do you have a dimension, or a problem?
Give us the dimension and we will list the match from stock. Describe the problem and engineering will look at it.
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