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Radome Seal Upgrade

Case Study: Radome Seal Upgrade.
From Four Days to One.

Partner: Rubbercraft Corporation of California (RCC)

Project Type: Seal Engineering and Retrofit Solution

This seal plays a critical role by sealing the gap between the radome cover and the aircraft body. This protects internal components from environmental contaminants, preserves the aerodynamic shape of the structure, maintains RF transparency for signal integrity, and provides mechanical cushioning and vibration damping. As is common for radome seals, electromagnetic interference (EMI) shielding is embedded within the seal, adding both functional complexity and cost.

Project Snapshot

Project Type

Seal Engineering and Retrofit Solution

Partner

Rubbercraft Corporation of California (RCC)

Market

Defense

Key Outcomes

4→1

Days to Install

+3

Days Mission Ready

1pc

vs. 4-Piece Prior

0

Field Splicing Req’d

Challenge

Key Issues Included

During a site visit to support a different product, RCC proactively collaborated with the customer to uncover operational inefficiencies. During discussions with the customer’s engineers about broader maintenance challenges, RCC identified a poorly spliced, multi-segmented radome seal that stood out both visually and functionally.

The seal was shipped in four pieces, requiring time-intensive manual splicing by technicians.

Moisture accumulation under the seal required manual notching in the field.

The current solution was unattractive, inefficient, and inconsistent in quality.

Color mismatch between the seal and aircraft body further degraded aesthetics and camouflage integrity.

Solution Development

From Discovery to Delivery

Discovery and Collaboration

Confirming the Problem

Customer engineers confirmed the splicing and manual notching process was a known challenge.
RCC proposed developing a single-piece, pre-spliced seal with a professionally manufactured drainage notch.

Tooling Investigation

Finding the Cost-Effective Path

After onsite evaluation of existing tooling, RCC arranged to have the tool shipped to its facility.
Rubbercraft Engineers determined the current tool could be modified to produce a full, molded prototype with the integrated notch.

Prototype & Fit Check

Validating the Solution

RCC fabricated a one-piece seal and shipped it to the base.
RCC coordinated with the customer’s Engineering and Operations to conduct a live fit check, with aircraft limited aircraft down time four days.

Final Optimization

Finishing the Solution

RCC proposed a color matched version to better match the aircraft’s finish and reduce visual impact.

Results

Measurable Impact

4→1

Installation time reduced from four days to one

+3

Days aircraft return-to-service accelerated

0

Field splicing or manual notching required

Installation time reduced from four days to one, significantly lowering labor costs and aircraft downtime.

Seamless, one-piece design eliminated field splicing and manual notching.

Aircraft return-to-service accelerated by three days, improving mission readiness.

Improved aesthetics, with a consistent color match to the aircraft skin.

Higher and more repeatable factory-built quality, eliminating variability of manual field work.

Key Success Factors

Why It Worked

Rubbercraft’s trusted customer relationships and hands-on technical engagement revealed critical, previously unseen challenges.

Open, solution-oriented communication with engineering and command personnel.

Strategic use of existing tooling to deliver a cost-effective and timely solution.

Ability to identify and act on obsolescence issues is often overlooked by competitors.

Replicable Approach

How We Engage Every Time

Engaged with end users and decision makers onsite.

Our engineer experts ask the right questions.

Proactively problem solve for inefficiencies or obsolescence.

Design practical solutions from our technical experience and end user feedback.

Deliver rapid quality with agility to iterate based on real-world testing.