General-purpose groove design. Based on standard AS568/ISO 3601-2 squeeze and fill targets. High pressure, extreme temperature, or exotic materials need extrusion-gap and compound-specific checks this tool doesn't do.
Engineering · sealing

O-Ring Groove Calculator

Cross-section in, groove dimensions out.
squeeze · fill · stretch
CS 3.53 mm · static

Choose the O-ring

metric
mm

Groove design

Field notes

Reading a groove spec

How it works

Squeeze, fill, and why both matter

An O-ring seals by being squeezed — compressed slightly smaller than its free cross-section when the groove closes. Too little squeeze and it can't maintain contact as things vibrate or wear; too much and friction, compression set and heat build-up shorten its life fast. The groove also needs to leave room: gland fill is how much of the groove volume the ring actually occupies, and it needs headroom for thermal expansion and fluid swell.

Worked example

A 3.53 mm cross-section (AS568 "139" series) static seal targets about 20% squeeze — a groove depth of roughly 2.8 mm. Switch the same O-ring to a dynamic (sliding or rotating) application and the target squeeze drops to around 12%, giving a deeper groove and less friction — the trade-off dynamic seals always make against static ones.

Why does a dynamic seal need less squeeze than a static one?

Squeeze is what makes the seal — but it's also what makes friction. A static seal never moves, so it can afford more squeeze for a more robust seal. A dynamic seal (a rod, piston or rotating shaft) pays for every percent of squeeze in friction, heat and wear, so the design target is deliberately lower.

What happens if gland fill is too high?

Above about 90% fill, the O-ring has nowhere to go as it heats up or absorbs fluid (swell) — it can hydraulic-lock in the groove, spike contact pressure, and extrude out through any clearance gap. Below about 70%, the ring can shift, twist, or fail to fully occupy the groove under pressure.

Radial vs face groove — what's the actual difference?

A face seal is squeezed between two flat surfaces closing together, like a lid — simple to design and assemble. A radial seal is squeezed between a shaft and a bore, sealing sideways — the standard choice for anything that slides or rotates, like a piston or rod.

Why only AS568 cross-section families, not exact dash numbers?

A dash number just pairs a standard cross-section with a standard inside diameter — the groove design itself depends only on the cross-section and seal type, not the specific ID. Entering your own ID here gives an exact, correct groove for any size, standard or custom, without needing to look up a dash-number table.