The Customer: A Data Center Enclosure Manufacturer in Need of Custom Gasket Sealing Solutions
Our customer is a global manufacturer of critical power infrastructure, including power distribution units (PDUs) and their enclosures, for the data center industry. Its products support mission-critical facilities for companies such as Google, Meta, and Amazon.
The manufacturer partnered with Trim-Lok to reduce assembly time, simplify installation, and improve sealing quality by developing a custom bonded gasket frame for its PDU enclosures.
The Challenge: Manual Enclosure Gasket Installation Slowing PDU Enclosure Production
The manufacturer’s production teams were manually cutting and applying bulk gasket trim on PDU enclosure frames, a process that took nearly three minutes per unit. Installing the gasket by hand added time to every unit and made it harder to achieve consistent placement and adhesion across production.
Because each gasket was measured and cut manually, slight variations in gasket length and corner fit could also impact sealing performance. This manual approach slowed production and made it challenging to achieve the same gasket fit and placement on every enclosure frame.
The Goal: Streamline PDU Enclosure Gasket Installation
The objective was clear: reduce assembly time and improve installation consistency with a more efficient custom gasket solution.
The manufacturer needed a partner with expertise in designing custom enclosure gaskets for high performance, mission-critical facility applications.
The Solution: A Custom Bonded Enclosure Gasket Frame Built for Faster Assembly
Trim-Lok collaborated closely with the manufacturer's engineering team to develop a custom bonded gasket frame tailored to the company's PDU enclosure. Using a polyethylene (PE) welding process, each gasket was precision-cut, bonded into a complete frame, and delivered ready to install, eliminating the need to measure, cut, and assemble bulk gasket material on the production line.
Engineering Collaboration
Leveraging its custom extrusion design expertise, Trim-Lok engineered a bonded gasket frame that balanced sealing performance, manufacturability, and ease of installation. Every aspect of the design was tailored to meet the customers’ enclosure and production requirements.
Material and Custom Fit
Each custom gasket was precision-manufactured to the exact dimensions of the PDU enclosure for a clean, repeatable fit. Trim-Lok cut, mitered, bonded, and assembled each trim seal into a continuous frame, allowing installers to pull the frame from the box and install it without making cuts on the production floor.
The result was a faster, more precise installation process that reduced waste while helping provide consistent sealing protection against dust, moisture, and other environmental factors.
3D CAD Design and Rapid Prototyping
Trim-Lok engineers used 3D CAD modeling to ensure accurate gasket fit, compression values, and enclosure interface before producing prototypes for testing within days. Prototype testing allowed the customer's engineering team to verify fit, form, and function before moving into production.
The Outcome
The finished bonded gasket frame transformed a labor-intensive installation process into a simple, ready-to-install solution. Installation time dropped from nearly three minutes to just 30 seconds—an 83% reduction—while improving assembly consistency, increasing production throughput, and delivering a more uniform seal across every PDU enclosure.
The Trim-Lok custom gasket frame solution is now in full production rollout, supporting the manufacturer’s mission to deliver fast, reliable solutions for mission-critical facilities across the data center industry.
Ready to Develop Your Own Solution? Trim-Lok is Your Custom Gasket Manufacturer
Whether you are designing enclosures for data centers, industrial facilities, or mission-critical systems, Trim-Lok offers expert support in custom gasket manufacture and design.
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