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Piston Seals

A piston seal seals the moving piston against the cylinder bore, separating the two pressure chambers of a double-acting hydraulic cylinder so fluid can't bypass from the high-pressure side to the low-pressure side.

FITCO hydraulic and pneumatic seals
Piston seal profiles - UNP/UHP, OE, DAS, DO-DLS types

Piston seal profiles: B7/UNP/UHP, OE, DAS, DO-DLS, and DK*DO types.

Overview

How it works

Unlike a rod seal, which seals against a fixed housing while the rod moves through it, a piston seal moves with the piston through a fixed bore — so it has to seal reliably at every point along the stroke, not just at rest. Internal (cross-port) leakage past a worn piston seal is one of the most common causes of a hydraulic cylinder losing holding force under load, which is why piston-seal wear life is usually the limiting factor in a cylinder's service interval.

Profiles

Available profiles

Profile

PS1

Single-element compact piston seal profile for standard-duty cylinders.

Profile

DA — Double Acting

Symmetrical profile sealing equally in both directions of travel.

Profile

PR — Piston Ring

PTFE-based ring style for high-speed or high-temperature service.

Materials

Which compound, and why

Material

Polyurethane (PU)

The default piston-seal material — extrusion and wear resistance under working pressure.

Material

NBR

Lower-cost option for moderate-pressure, moderate-temperature duty.

Material

PTFE (Virgin, Glass, Bronze, Graphite)

Piston-ring profiles in high-speed or high-temperature service needing very low friction.

Applications

Where used

Fitted around the piston of double-acting hydraulic cylinders across mobile equipment, industrial presses and machine tools.

How Piston Seals Work

A piston seal sits in a groove on the piston and seals against the cylinder bore wall. It separates the high-pressure and low-pressure sides of the piston, converting hydraulic fluid pressure into linear force and motion. The seal must provide zero-bypass sealing to maintain full actuator force while operating at low friction for smooth, controllable movement.

Unlike rod seals which seal against a polished shaft, piston seals operate against a honed cylinder bore with a coarser surface finish (Ra 0.2–0.4 µm). They experience pressure from alternating sides as the cylinder extends and retracts, and must resist extrusion into the clearance gap between the piston and bore at high pressures.

Piston Seal Types

Compact piston seals (UNP/UHP) are single-piece polyurethane or NBR seals designed for medium-duty applications up to 250 bar. They combine pressure activation with a pre-loaded lip for reliable sealing even at low pressures. Double-acting piston seals (DAS) provide symmetrical sealing in both directions using a combined PTFE slide ring and elastomer energiser, suitable for pressures up to 400 bar with very low friction.

OE type seals use an O-ring energiser behind a PTFE cap to provide consistent low-friction sealing across a wide temperature range. DO-DLS type seals feature a deep-section design for heavy-duty cylinders operating above 400 bar. For mobile hydraulic applications with high side loads, piston seals are combined with guide rings to prevent metal-to-metal contact between the piston and cylinder bore.

Applications and Performance

Piston seals are essential components in hydraulic cylinders used across construction equipment (excavators, loaders, cranes), agricultural machinery (tractors, harvesters), industrial presses, injection moulding machines, marine steering gear, and mining equipment. In mobile hydraulic applications, piston seals must tolerate contaminated oil, wide temperature swings, shock loads and irregular maintenance intervals while maintaining leak-free performance.

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