O-Rings play a key role in sealing applications, preventing leaks, and improving efficiency in everything from engines to medical devices. Choosing the right material is more important as demand grows for custom Silicone 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 rubber O-ring market is projected to exceed $10 billion by 2026, driven by the need for customization and improved performance.
In this blog, we will provide a comprehensive comparison of 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 its durability in extreme environments. It performs reliably in a wide temperature range of –20°C to 200°C (-4°F to 392°F), with some grades handling even higher temperatures. 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, especially when performance and longevity are most important.
Read More– Top 7 Things to Know about Viton Rubber
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 medical, food processing, and electronics industries.
The typical gasket 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-approved silicone produces custom silicone rings that are safe for both food and medical use, meeting strict regulatory standards.
Read More– Know About Silicone Rubber O Ring & Its Properties
Comparative Analysis of Viton vs Silicone O-Rings for Performance and Application Differences
Understanding how each material performs under different conditions is key when deciding between Viton and Seal 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 handles a broader 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 (similar to Viton) is tough and offers excellent 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 less suited for outdoor ozone exposure.
Best for strength and durability: Viton
Best for static, flexible seals: Silicone
4. Environmental Resistance
Environmental factors, such as ozone, UV radiation, and weather, can affect seal performance.
Viton resists ozone, oxidation, and high temperatures, making it suitable for industrial environments exposed to chemicals and heat.
Silicone offers excellent UV and ozone resistance, performing well in outdoor, pharmaceutical, and clean applications.
Best for chemical/heat exposure: Viton
Best for outdoor or FDA-grade uses: Silicone
Viton vs Silicone O-Rings: Quick Comparison Table
| 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) | Softer and more flexible, prone to tearing in high-stress conditions |
| 3. Mechanical Properties | Strong, durable, resists tearing, compression, and abrasion(FKM material) | Excellent UV and ozone resistance. Great for outdoor and clean environments |
| 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 |
Real-World Applications of Viton and Silicone O-Rings Across Key Industries
Both Viton and Square O-rings are used across a wide range of industries. Each material offers benefits that make it more suitable for specific environments and regulations.
Let’s explore how they perform in different sectors.
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 handle aggressive chemicals and high temperatures.
With a typical Viton gasket 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
Materials must be non-toxic, biocompatible, and resistant to sterilization processes in medical applications. 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. EPDM 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 for food-grade gaskets, pumps, and dispensers.
4. Aerospace
Aerospace applications require materials that can withstand extreme temperatures, pressure variations, and exposure to jet fuel 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 shapes 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 that will improve the performance of your equipment. The choice depends on factors such as 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.
Large 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 tailored 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 complete production runs. Our materials comply with USP Class VI, passing Sections 87 and 88 biocompatibility tests for medical and FDA-grade use.
With a focus on quality, innovation, and the shortest lead times in the industry, we take pride in being a reliable and 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.
Do you 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.
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 rubber or elastomer materials.
When should you avoid using Viton seals?
Viton seals should be avoided in continuous freezing conditions or when exposed to strong polar solvents. Elastostar can recommend better alternatives, such as Silicone or EPDM. 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 and 10 years, depending on the 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 use, or medical applications. Our team can help you make the proper selection for your needs.
