O-rings play a key role in sealing applications, preventing leaks, and efficiency in everything from engines to medical devices. Choosing the right material is more important as demand grows for custom O-rings. Viton and Silicone rubber are the most widely used options, each with unique properties suited for different environments. According to market reports, the global O-ring market is projected to exceed $10 billion by 2026, driven by customization and performance needs.
In this blog, we will comprehensively compare Viton and Silicone O-rings to help you select the best fit for your project.
What are Viton O-Rings?
Viton is a high-performance synthetic rubber developed by DuPont and classified as a fluoroelastomer. It’s known for its exceptional resistance to high temperatures, aggressive chemicals, fuels, and oils, making it ideal for demanding sealing applications across the automotive, aerospace, and industrial sectors.
A Viton O-ring excels in durability in extreme environments. It performs reliably in a wide Viton O-ring temperature range of -20°C to 200°C (-4°F to 392°F), with some grades handling even higher. This heat resistance, combined with excellent chemical stability, helps extend the life of seals and reduce maintenance needs.
A Viton seal is typically used where other materials fail and is the go-to choice when performance and longevity matter most.
What are Silicone O-rings?
Silicone O-rings are made from a versatile, flexible elastomer and are widely used in applications that require excellent thermal stability, low toxicity, and superior flexibility. Known for their clean, non-reactive properties, they’re often the top choice in industries like medicine, food processing equipment, and electronics.
The typical silicone O-ring temperature range is impressive—from -60°C to 230°C (-76°F to 446°F), for both high-heat and low-temperature environments. While they aren’t suited for use with fuels or strong acids, their ability to maintain sealing integrity under thermal stress makes them highly reliable.
For applications requiring hygiene or compliance, FDA silicone produces custom silicone rings that are safe for food and medical use and meet strict regulatory standards.
Viton vs Silicone -Differences You Need to Know
Understanding how each material performs under different conditions is key when deciding between Viton and Silicone O-rings.
1. Temperature Resistance
Viton rubber performs exceptionally well in high-heat environments, with a typical operating range of -20°C to 200°C (-4°F to 392°F). Some specialized grades can go even higher.
Silicone, however, handles a wider temperature range from -60°C to 230°C for cold environments and consistent heat exposure.
Best for high heat: Viton
Best for extreme cold: Silicone
2. Chemical Compatibility
Material choice directly impacts longevity and safety for chemical, oil, or fuel applications.
Viton material is highly resistant to aggressive chemicals, fuels, and solvents, which is why it’s trusted in automotive and industrial settings.
Fluorosilicone O-rings offer better chemical resistance than standard silicone, especially for fuel contact, but still don’t perform as well as Viton under harsh exposure.
Best for chemical-heavy environments: Viton
Suitable for moderate chemical exposure: Fluorosilicone
3. Mechanical Properties
Durability, flexibility, and resistance to wear all matter for long-term sealing performance.
FKM O-ring material (like Viton) is tough and offers great resistance to compression, abrasion, and tearing. It performs well in both dynamic and static applications.
Silicone is softer and easier to compress but more prone to damage under mechanical stress. Compared to EPDM, Viton is more durable in chemically aggressive environments but is less suited for outdoor ozone exposure.
Best for strength and durability: Viton
Best for static, flexible seals: Silicone
4. Environmental Resistance
Environmental factors like ozone, UV, and weather can affect seal performance.
Viton resists ozone, oxidation, and high temperatures for industrial environments exposed to chemicals and heat.
Silicone offers excellent UV and ozone resistance, performing well in outdoor, medical, and clean applications.
Best for chemical/heat exposure: Viton
Best for outdoor or FDA-grade uses: Silicone
Read More– Viton vs Silicone Rubber: What is the Best Choice for your Business?
Viton vs Silicone O-Rings
| Property | Viton O-Rings | Silicone O-Rings |
| 1. Temperature Resistance | -20°C to 200°C (up to 250°C for some grades)Excellent for high-heat use | -60°C to 230°CIdeal for cold and moderate heat environments |
| 2. Chemical Compatibility | Outstanding resistance to fuels, oils, and harsh chemicals(Viton material) | Limited resistanceFluorosilicone improves fuel compatibility slightly |
| 3. Mechanical Properties | Strong, durable, resists tearing, compression, and abrasion(FKM material) | Softer and more flexibleProne to tearing in high-stress conditions |
| 4. Environmental Resistance | Excellent against ozone, oxidation, and high temperatures(Viton temperature) | More affordable Ideal for FDA-grade and general-purpose sealing |
| Cost | Higher costBest for demanding applications | Higher cost: Best for demanding applications |
What are the Real-World Applications of Viton and Silicone O-Rings Across Key Industries?
Both Viton and Silicone O-rings are used across a wide range of industries. Each material offers benefits that make it more suitable for specific environments and regulations.
1. Automotive
In the automotive industry, durability under heat and exposure to fuel is critical. Viton O-rings are widely used in fuel systems, engines, and transmission components due to their ability to withstand aggressive chemicals and high temperatures.
With a typical Viton O-ring temperature range of up to 200°C (392°F), they perform reliably even in extreme engine conditions, reducing the risk of seal failure.
2. Medical Devices
In medical and pharmaceutical applications, materials must be non-toxic, biocompatible, and resistant to sterilization processes. Silicone is often the preferred material because of its purity and flexibility.
FDA-approved silicone rubber formulations are used in seals for ventilators, infusion pumps, and other sensitive medical devices. Silicone’s ability to maintain its properties at varying temperatures makes it safe for repeated sterilization.
3. Food & Beverage
Sealing components in food and beverage equipment must meet strict hygiene and safety standards. Silicone O-rings made with FDA-approved seals are a top choice in this space.
They are resistant to moisture, steam, and cleaning agents and won’t affect the taste or purity of food products. Their flexibility and cleanliness are ideal for food-grade gaskets, pumps, and dispensers.
4. Aerospace
Aerospace applications demand materials that can handle extreme temperatures, pressure variations, and exposure to jet fuels or hydraulic fluids.
Viton is frequently used in aerospace fuel systems, engine compartments, and fluid sealing systems. FDA O-rings are also required in cabin environments or food-handling areas on aircraft, and silicone fulfills this role well due to its safety and low toxicity.
5. Electronics
The electronics industry uses O-rings for sealing enclosures, connectors, and protective casings.
Silicone is often molded into extruded rubber shape parts for cable seals, gaskets, and housing protection. It provides excellent resistance to heat, UV light, and environmental exposure, essential for consumer electronics and industrial-grade equipment.
How to Choose the Right O-Ring for Your Application?
Selecting the right O-ring is crucial for maintaining a secure, leak-free seal and ensuring the performance of your equipment. The choice depends on temperature, chemical exposure, pressure, and industry-specific standards.
Viton O-rings are best suited for high-performance applications involving heat, oils, fuels, and aggressive chemicals. They are commonly used in automotive, aerospace, and industrial systems where long-term durability is essential.
Silicone O-rings are ideal for clean, non-reactive environments. Their flexibility and purity make them perfect for food, medical, and electronic applications, especially where FDA-approved materials are required.
If your project requires specific shapes, tolerances, or certifications, working with a custom O-ring manufacturer can ensure the O-rings are customized to your needs.
Why Choose Elastostar Rubber Corporation?
At Elastostar Rubber Corporation, we specialize in high-performance sealing solutions, including extruded seals, custom O-rings, and rubber sealing strips designed to meet the most demanding applications. We support our customers in everything from reverse engineering and design consultation to prototypes and full production runs. Our materials comply with USP Class VI, passing Section 87 and 88 biocompatibility tests for medical and FDA-grade use.
With a focus on quality, innovation, and the shortest lead time delivery in the industry, we take pride in being a reliable, responsive partner for custom rubber components made to your specifications.
Recommended Reads
- How to Select the Right Silicone O-Rings for Industrial Applications
- Top 7 Things to Know About Viton Rubber
- Custom Silicone O-Rings: Leading Manufacturer in the USA and Canada
Conclusion
Choosing between Viton and Silicone O-rings comes down to understanding your application’s temperature range, chemical exposure, mechanical demands, and compliance needs. Viton excels in high-heat, chemical-heavy environments, while Silicone is ideal for flexible, clean, and FDA-compliant uses.
At Elastostar Rubber Corporation, we offer custom-engineered O-rings and sealing solutions customised to your specifications, whether for automotive, medical, or industrial use.
Need help selecting the right material or designing a custom seal? Contact us today to speak with our technical team and get started on your solution with the shortest lead time in the industry.
FAQs
Which is better: Viton or Silicone O-rings?
Viton is better for high temperatures, oils, and chemicals, while Silicone is ideal for cold environments and FDA-compliant applications. At Elastostar, we offer both materials and can help you choose the right one. Contact us for expert guidance from a trusted custom O-ring manufacturer.
What are the disadvantages of Viton O-rings?
Viton does not perform well at very low temperatures and is less resistant to some solvents, such as ketones and esters. It is also more expensive than many standard elastomers.
When should you avoid using Viton seals?
Viton seals should be avoided in continuous freezing conditions or where exposure to strong polar solvents occurs. Elastostar can recommend better alternatives, such as Silicone or EPDM, for such environments. Contact us to discuss your specific requirements.
What seals better than Silicone O-rings?
Viton and FKM seals provide better sealing in high-heat and chemically aggressive environments than Silicone. However, Silicone is preferred for clean, flexible, and FDA-grade applications.
How long do Viton O-rings last?
Viton O-rings typically last between 5 to 10 years, depending on conditions. At Elastostar, we manufacture long-lasting Viton seals and extruded rubber sealing products. Contact us to explore custom options.
What is the best O-ring material overall?
The best material depends on the application. Viton is ideal for heat and chemicals, while Silicone is better for low temperatures, food-grade, or medical use. Our team can help you make the right selection for your needs.
