GORE GUA1001-1/GSC21-95201-0111 (1-Roll)

GORE™ SKYFLEX™ Aerospace Materials

Overview

GORE™ SKYFLEX™ Aerospace Materials are a range of expanded PTFE (ePTFE)-based sealing, gap-filling, and surface protection materials designed for aerospace applications. They are engineered to provide reliable environmental sealing, abrasion resistance, corrosion protection, and fluid resistance across a wide range of aircraft structures and operating conditions. Unlike liquid sealants, these non-curing materials maintain performance over repeated opening and closing cycles, reducing maintenance and lifecycle costs.

Key Technical Characteristics

• Base Material: Expanded polytetrafluoroethylene (ePTFE)
• Forms: Tapes and gaskets (various series: 100, 110, 200, 500, 520, 700, 720, 730, 1600)
• Operating Temperature Range: approx. -73°C to +177°C (varies by adhesive/system)
• Chemical Resistance: Resistant to aviation fluids, fuels, oils, hydraulic fluids (series-dependent)
• Flammability Compliance: Meets aerospace fire safety standards (e.g. FAR 25.853)
• Storage Life: Up to 10 years (no adhesive), ~2 years (with adhesive)

Core Performance Benefits

• Reliable sealing under vibration, flexing, and repeated access cycles
• Excellent resistance to fuels, oils, de-icing fluids, and hydraulic fluids
• Prevents abrasion and corrosion at faying surfaces
• Maintains compression without squeeze-out (unlike liquid sealants)
• Lightweight, flexible, and non-curing for simplified installation
• Non-hazardous material with low environmental impact

Typical Applications

• Aircraft access panels and fairings
• Leading edge and aerodynamic surface interfaces
• Dry-bay and fuel system sealing
• Helicopter structures and tail booms
• Cargo floorboards and structural interfaces
• Engine cowlings and maintenance access points
• Light assembly and multi-cycle opening panels

Material Engineering & Design Features

The material is based on engineered ePTFE, modified through proprietary processing to control density, compressibility, and structural memory. This allows different series to be optimized for specific use cases such as high vibration environments, fuel exposure, or large gap filling.

Different product series are tailored for specific performance needs:

• 100/110 Series: General sealing and abrasion protection
• 500/700 Series: Gap filling and structural sealing
• 520/720 Series: Enhanced fuel and fluid resistance applications
• 730 Series: High resistance to aggressive aviation fluids including hydraulic fluids

Installation & Handling

• No curing time required (ready-to-use installation)
• No mixing, masking, or pot-life limitations
• Can be applied directly to prepared surfaces
• Reduces assembly and maintenance time compared to liquid sealants
• Designed for consistent compression and repeat access performance

Environmental & Compliance Notes

• Non-hazardous material classification
• No special waste handling required under normal use
• Complies with aerospace fire, UV, and chemical exposure standards
• Avoid high-temperature incineration or grinding without ventilation controls

Key Advantages for Aerospace Use

• Improves seal reliability in dynamic structural interfaces
• Reduces lifecycle maintenance and resealing requirements
• Provides consistent performance across manufacturing tolerances
• Supports faster aircraft assembly and turnaround times
• Enhances protection of corrosion-inhibiting coatings