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Global O-Ring and Seal has developed these o-ring groove design and gland dimension guidelines to help you size a correct gland for face/flange, static, dynamic and dovetail seals. Use the interactive O-Ring Groove Design Calculator below to apply them in seconds — choose an AS568 series and groove type to get gland depth, width, squeeze and corner radii, with built-in compression, extrusion/pressure and concentricity checks.
Numerous factors go into a gland/groove design — static or dynamic application, pressure, the fluid being sealed, and the tolerances of both the o-ring and the groove — so treat the calculator as a starting point and confirm it against your application. The full design tables, dimensional references and engineering guidance behind the tool are in the Supporting Documentation below.
Groove cut around a piston or shaft; the O-ring is squeezed between the groove bottom and the bore wall. Not sure? Piston/shaft is the most common — pick it and adjust.
Piston / shaft groove — the O-ring is squeezed between the groove bottom and the bore wall. Tap a field below and its dimension lights up.
in
Smaller of the two diameters.
in
Larger of the two diameters.
in
Radial depth. Auto = (OD−ID)÷2.
in
Axial width of the groove.
The finder uses published O-ring design rules — target squeeze (judged by cross-section), gland-fill, and stretch. Inch (AS568) sizes follow the Parker O-Ring Handbook ORD 5700 tables; metric sizes follow ISO 3601-2 (Housing dimensions), with off-standard cross-sections shown as general guidance. Sizes are matched against Global O-Ring’s stocked AS568 and metric sizes. Results are a starting point; final selection should account for tolerances, fluid/thermal swell, pressure, and material. Want a person to confirm it? Request a quote or call 832-448-5550 — most of what we sell is in stock in Houston.
Related: Shop all O-Rings · O-Ring Groove Design guide
Static radial gland — designed clearance gap, no motion.
in
Nearest stocked AS568 dash in this series — with a machine-to-fit tip if your ID is off-standard.
Design Validator
Real-time checks against the methodology described further down this page — compression-ratio extremes, extrusion-pressure limits, and concentric clearance.
Compression Check
Squeeze at nominal dimensions and at both tolerance extremes. Each value is checked against the published squeeze range for the selected series and groove type.
Extrusion / Pressure Check
Enter your application pressure, durometer, and clearance gap. The calculator returns the max safe pressure for that combination (Parker EB-1010 limits) and whether your design fits.
psi
in
Concentricity / Clearance Helper
No measured clearance handy? Enter bore and shaft/piston diameters. Assume all clearance can shift to one side — the full diametric clearance is what the extrusion check needs.
in
in
Extrusion-pressure limits derived from the Parker O-Ring Handbook (ORD 5700 / EB-1010). Values assume continuous pressure at room temperature on elastomeric compounds (Buna-N, FKM/Viton, EPDM). For FFKM, PTFE, polyurethane, high-temperature service, pulsing pressure, or Rapid Gas Decompression, request engineering review.
Sources & standards. Inch gland dimensions and squeeze ranges follow the Parker O-Ring Handbook (ORD 5700) and SAE AS4716: static glands per Design Chart 4-2, face seals per Design Chart 4-3, dovetail glands per the dovetail charts, and dynamic glands per the ORD 5700 reciprocating-seal tables. Cross-section sizes & tolerances per SAE AS568 and ISO 3601-1; metric housing per ISO 3601-2. Extrusion limits per ORD 5700 / Parker EB-1010.
Values are a starting point — the final design must account for tolerance extremes, fluid swell, thermal expansion, and concentricity. Request a quote or call 832-448-5550.
Values are a starting point — the final design must account for tolerance extremes, fluid swell, thermal expansion, and concentricity. Request a quote or call 832-448-5550.
Related: Shop all O-Rings · O-Ring Groove Design guide
'+
''+
'
';
}
function customPanel(depth, gID, gOD, idealPct, hasPass){
var sid=idealPct;
var csIdeal = depth/(1-sid/100);
var idIdeal = (state.seal==="rod"||state.seal==="face-internal") ? (gOD-2*csIdeal) : gID;
var spec = "O-ring ID ≈ "+dimBoth(idIdeal)+" · cross-section ≈ "+dimBoth(csIdeal)+
" · groove: ID "+dimBoth(gID)+", OD "+dimBoth(gOD)+", depth "+dimBoth(depth);
var head = hasPass ? "Prefer an exact fit? A custom size hits the ideal squeeze" : "This looks like a non-standard groove";
var lead = hasPass
? "The standard size(s) above will work. If you want squeeze right in the middle of the range, a made-to-spec O-ring is the exact match:"
: "No off-the-shelf AS568 size lands cleanly in this groove — which is normal for grooves that weren’t cut to a standard. Here’s the O-ring that fits it, which we can make to order:";
return ''+head+' '+sizeLine+'
'+
''+tag+''+
metric("Squeeze", r.sq.toFixed(1)+"%", sqCls, sqNote)+
metric(r.dimLabel, (r.dim>=0?"+":"")+r.dim.toFixed(1)+"%", dimCls, dimNote)+
metric("Gland fill", r.fill==null?"—":r.fill.toFixed(0)+"%", fillCls, fillNote)+
'
'+
''+
'
'+
'
'+
''+shopLabel+''+
'Quote this size'+
''+why+'
'+
'Squeeze target '+Math.round(r.sqMin)+'–'+Math.round(r.sqMax)+'% · '+r.sqSrc+'
'+
''+
'
';
}
function render(){
var box=$("#fResults");
if(metricState==="idle"){ loadMetric(function(){ if(metricState==="loaded") render(); }); }
var gID=num($("#fID")), gOD=num($("#fOD")), depth=num($("#fDepth")), width=num($("#fWidth"));
// need at least (ID & OD) or depth, plus width
if((gID==null||gOD==null) && depth==null){
box.innerHTML=''+head+'
'+lead+'
'+ ''+spec+'
'+
''+
''+
'Request this custom O-ring'+
'
'+
'Options for non-standard sizes: '+ 'custom molded O-rings, '+ 'vulcanized (spliced) O-rings for larger IDs, or call 832-448-5550 and read off your four measurements.
'+ 'Enter at least the groove ID and OD (or a depth), plus the width, then press Find my O-ring.
'; return;
}
var giIn=gID!=null?toIn(gID):null, goIn=gOD!=null?toIn(gOD):null,
dIn=depth!=null?toIn(depth):null, wIn=width!=null?toIn(width):null;
if(giIn!=null&&goIn!=null&&goIn<=giIn){
box.innerHTML='Groove OD must be larger than groove ID. Double-check the two diameters.
'; return;
}
var isFace = state.seal.indexOf("face")===0;
if(isFace){
if(wIn==null && giIn!=null && goIn!=null) wIn=(goIn-giIn)/2;
if(dIn==null){ box.innerHTML='For a face seal, enter the axial groove depth (how deep the groove is cut into the face).
'; return; }
if(wIn==null){ box.innerHTML='Add the groove width (or the ID and OD so we can work it out).
'; return; }
} else {
if(dIn==null && giIn!=null && goIn!=null) dIn=(goIn-giIn)/2;
if(wIn==null){ box.innerHTML='Add the groove width so we can check gland fill (how much room the O-ring has).
'; return; }
if(dIn==null){ box.innerHTML='Enter the groove depth, or both ID and OD so we can work it out.
'; return; }
}
var ev=evaluate(giIn,goIn,dIn,wIn);
var depthUsed=ev.depth, mode=ev.mode;
if(depthUsed==null||depthUsed<=0){
box.innerHTML='Couldn’t work out the groove depth. Enter it directly.
'; return;
}
if(!isFace && depth==null){ $("#fDepth").value=(state.unit==="mm"?(depthUsed*25.4):depthUsed).toFixed(3); }
if(isFace && width==null){ $("#fWidth").value=(state.unit==="mm"?(wIn*25.4):wIn).toFixed(3); }
var allPass=ev.list.filter(function(r){return r.ok;});
var asPass=allPass.filter(function(r){return r.sys!=="M";}); // AS568 (inch)
var mPass =allPass.filter(function(r){return r.sys==="M";}); // metric
var asClosest=ev.list.filter(function(r){return r.sys!=="M";})[0]; // best AS568 even if it doesn't fully pass
var mClosest =ev.list.filter(function(r){return r.sys==="M";})[0];
var cards=[];
if(asPass.length){ // inch fits -> AS568 leads, metric is the bonus option
cards.push({r:asPass[0],tag:"Best match"});
if(mPass.length) cards.push({r:mPass[0],tag:"Also fits — metric"});
if(asPass[1]&&cards.length<3) cards.push({r:asPass[1],tag:"Alternative"});
} else if(mPass.length){ // metric fits but no standard inch size does -> always still surface an AS568
cards.push({r:mPass[0],tag:"Best match"});
if(asClosest) cards.push({r:asClosest,tag:"Closest AS568"});
if(mPass[1]&&cards.length<3) cards.push({r:mPass[1],tag:"Alternative"});
} else { // nothing passes cleanly -> show the closest of each
if(asClosest) cards.push({r:asClosest,tag:"Closest AS568"});
if(mClosest) cards.push({r:mClosest,tag:"Closest metric"});
}
var html='';
html+='Using gland depth '+dimBoth(depthUsed)+
' · '+(state.seal.indexOf("face")===0?"face seal":state.motion+" seal")+
'. Squeeze is judged by cross-section — inch sizes per AS568 / Parker O-Ring Handbook ORD 5700, metric per ISO 3601-2. Each result below shows the target range and source it was checked against.
';
html+='';
if(cards.length){
cards.forEach(function(c){ html+=scnCard(c.r, c.tag, depthUsed); });
} else {
ev.list.slice(0,3).forEach(function(r){ html+=scnCard(r,"Closest standard",depthUsed); });
}
html+='
';
if(!allPass.length){ html+=customPanel(depthUsed, giIn!=null?giIn:(goIn-2*depthUsed), goIn!=null?goIn:(giIn+2*depthUsed), MODE_IDEAL[mode], false); }
box.innerHTML=html;
var copyBtn=document.getElementById("fCopy");
if(copyBtn){ copyBtn.addEventListener("click",function(){
var t=document.getElementById("fSpec").textContent;
if(navigator.clipboard){ navigator.clipboard.writeText(t); copyBtn.textContent="Copied ✓"; setTimeout(function(){copyBtn.textContent="Copy these specs";},1500); }
}); }
}
// ---- 3-of-4 dimensions: auto-calculate & lock the dependent field ----
var FMAP={id:"#fID",od:"#fOD",depth:"#fDepth",width:"#fWidth"};
var fLocked=null;
function fLockEl(el,on){ if(!el)return; el.disabled=!!on; var c=el.closest(".gc-dim"); if(c)c.classList.toggle("is-locked",!!on); }
function fRaw(el){ var x=parseFloat(el.value); return isNaN(x)?null:x; }
function fFmt(x){ return (Math.round(x*1000)/1000).toString(); }
function syncLock(){
var isFace=state.seal.indexOf("face")===0;
var third=isFace?"width":"depth", free=isFace?"depth":"width";
fLockEl($(FMAP[free]),false);
function uv(k){ if(k===fLocked) return null; return fRaw($(FMAP[k])); }
var vid=uv("id"), vod=uv("od"), vth=uv(third);
["id","od",third].forEach(function(k){ if(k!==fLocked) fLockEl($(FMAP[k]),false); });
var have=(vid!=null?1:0)+(vod!=null?1:0)+(vth!=null?1:0);
if(have>=2){
if(vid!=null&&vod!=null){ if(vod>vid){ fLocked=third; var e=$(FMAP[third]); e.value=fFmt((vod-vid)/2); fLockEl(e,true);} else { fLocked=null; } }
else if(vid!=null&&vth!=null){ fLocked="od"; var e2=$(FMAP.od); e2.value=fFmt(vid+2*vth); fLockEl(e2,true); }
else { if(vod>2*vth){ fLocked="id"; var e3=$(FMAP.id); e3.value=fFmt(vod-2*vth); fLockEl(e3,true);} else { fLocked=null; } }
} else { fLocked=null; }
}
function resetLocks(){ fLocked=null; ["id","od","depth","width"].forEach(function(k){ fLockEl($(FMAP[k]),false); }); }
["#fID","#fOD","#fDepth","#fWidth"].forEach(function(s){ var el=$(s); if(el) el.addEventListener("input",syncLock); });
// wire toggles
$("#fSeal").addEventListener("click",function(e){var b=e.target.closest("button");if(!b)return;state.seal=b.getAttribute("data-seal");
$("#fSeal").querySelectorAll("button").forEach(function(x){x.classList.toggle("is-active",x===b);});
$("#fSealHint").textContent=SEALHINT[state.seal];
$("#fMotion").style.display = state.seal.indexOf("face")===0 ? "none":"flex";
if(fLocked){ $(FMAP[fLocked]).value=""; fLocked=null; } syncLock();
if($("#fResults").innerHTML.trim()!=="") render();
});
$("#fMotion").addEventListener("click",function(e){var b=e.target.closest("button");if(!b)return;state.motion=b.getAttribute("data-motion");
$("#fMotion").querySelectorAll("button").forEach(function(x){x.classList.toggle("is-active",x===b);}); if($("#fResults").innerHTML.trim()!=="")render();});
$("#fUnit").addEventListener("click",function(e){var b=e.target.closest("button");if(!b)return;state.unit=b.getAttribute("data-unit");
$("#fUnit").querySelectorAll("button").forEach(function(x){x.classList.toggle("is-active",x===b);});
root.querySelectorAll("[data-unitlbl]").forEach(function(x){x.textContent=state.unit;});
syncLock();
if($("#fResults").innerHTML.trim()!=="")render();});
$("#fGo").addEventListener("click",render);
$("#fClear").addEventListener("click",function(){["#fID","#fOD","#fDepth","#fWidth"].forEach(function(s){$(s).value="";});resetLocks();$("#fResults").innerHTML="";});
root.querySelectorAll(".gc-dim input").forEach(function(inp){inp.addEventListener("keydown",function(e){if(e.key==="Enter")render();});});
})();
- Verify the gap measurement — for an O-ring seal the diametric clearance is normally a few thousandths of an inch, so a value this large usually means a unit or decimal-point error.
- Bring the clearance within the chart (≤ 0.020″) with tighter machining or centering bearings, then re-check.
- If the large gap is genuinely required, request engineering review → — it needs a custom anti-extrusion solution.
- Add 1 backup ring — brings the limit to "+maxWithBackup.toLocaleString()+" psi for "+state.durometer+"A.
- If your design already runs at the high end of "+state.durometer+"A, consider stepping the durometer up one notch.
- Reduce the clearance gap (tighter machining or bearings).
- "+lis+"
ⓘ ")):"";} function renderDuroCompare(gap,isDynamic,pressure){ if(!vDuroCompare)return; var duros=[70,80,90],head="",rNo="",rBu="",rVerd=""; duros.forEach(function(d){ var act=(d===state.durometer)?" class=\"gc-dcmp-active\"":""; var mnb=lookupExtrusion(d,gap,isDynamic),mwb=backupLimit(d,isDynamic,gap); head+="
'+cap+'
| '+head+' |
|---|
| Max — no backup | '+rNo+'
| With 1 backup | '+rBu+'
| Your design | '+rVerd+'
Enter a target ID in inches.
'; return; }
var key=elSeries.value, list=sizesForSeries(key);
if(!list.length){ elOut.innerHTML='No AS568 sizes found for this series.
'; return; }
list.sort(function(a,b){ return Math.abs(a.id-tid)-Math.abs(b.id-tid); });
var best=list[0], delta=tid-best.id, adelta=Math.abs(delta), csNom=DATA.series[key].cs;
var html='';
if(adelta<=0.005){
html='AS568 -'+best.d+' — standard fit ✓
'+ 'Your target ID '+f3(tid)+'″ matches standard -'+best.d+' (ID '+f3(best.id)+'″, CS '+f3(csNom)+'″). Gland dimensions for this size are shown below.
'+ 'Shop -'+best.d+' →'+ 'Request a quoteClosest standard: AS568 -'+best.d+'
'+ 'Your ID '+f3(tid)+'″ is '+f3(adelta)+'″ '+dir+' than standard -'+best.d+' (ID '+f3(best.id)+'″, CS '+f3(csNom)+'″). '+ 'Machining the groove root to '+f3(best.id)+'″ lets you use an in-stock, off-the-shelf -'+best.d+' instead of a custom size.
'+ 'Shop -'+best.d+' →'+ 'Quote a custom '+f3(tid)+'″ IDWant to keep your exact ID '+f3(tid)+'″? We can make a custom O-ring to your dimension — use “Quote a custom” above.
';
}
elOut.innerHTML=html;
}
elGo.addEventListener("click",recommend);
elTID.addEventListener("keydown",function(e){ if(e.key==="Enter") recommend(); });
elSeries.addEventListener("change",function(){ if(elTID.value) recommend(); });
})();
render();
})();
Supporting Documentation
Reference tables, dimensional guidance and engineering notes behind the o-ring groove design calculator above.