Diaphragm Seal Manufacturing
At PCI Instruments, our diaphragm seals—also known as hygienic or chemical seals—are engineered to suit your pressure sensing instruments and diverse process applications. With over 25 years of experience and a state-of-the-art production facility in Britain, we manufacture diaphragm seals that deliver outstanding performance even in the most demanding environments.
For more detailed information on our diaphragm seal manufacturing capabilities or to request a quote, please visit our Diaphragm Seals and Instruments page. Our team is on hand to discuss your specific requirements and provide expert advice on the best solution for your application.
Our Manufacturing Process
Our manufacturing process combines precision engineering with advanced production techniques to ensure the highest quality diaphragm seals & custom made Diaphragm Pressure Gauges. We utilise in-house CNC lathes, laser welders, and rigorous quality control systems to produce both standard and custom diaphragm seals.
Our CNC machining and laser welding techniques guarantee that every component is manufactured to strict tolerances. This precision is critical for ensuring the reliability and accuracy of your pressure measurement systems.
An all-welded design is a cornerstone of our manufacturing process. By eliminating potential leak points, our seals provide a robust, leak-proof barrier that protects both the fill fluid and the process medium. This design is especially important in applications where even microscopic leaks can lead to system failures.
For aggressive applications where standard stainless steel (grade 316) is not sufficient, we offer exotic metal diaphragm seals. Using our specialist CNC welding process, we can bond materials such as tantalum to a stainless steel body—delivering a cost-effective solution compared to constructing an entire flange from an exotic metal. We also offer wetted parts in Duplex, Hastelloy, Inconel, Monel, Titanium, Zirconium, and coatings such as Gold, Rhodium, PFA, and PTFE.
Exotic Metal Material Selection & Quality Assurance
Quality begins with our raw materials, which are sourced from trusted suppliers in the EU and USA. Our standard diaphragm seals are primarily manufactured from 316 stainless steel—a material widely recognised in the pharmaceutical and food industries for its excellent corrosion resistance and hygienic properties.
Rigorous Quality Checks: Every diaphragm seal undergoes comprehensive testing, including helium leak testing up to 10⁻¹⁰ mbar·l/s, to ensure there are no microscopic holes or defects that could compromise performance. To ensure that our manufacturing processes adhere to the highest quality standards, we follow stringent protocols that comply with both international and UK-specific regulations. For further insights into these standards, please visit the British Standards Institution (BSI) Group.
Certifications & Compliance: We adhere to strict industry standards, ensuring that our manufacturing processes meet or exceed international quality benchmarks. Our products are designed with regulatory compliance in mind, which is essential for applications in highly controlled environments.
We offer diaphragms and wetted parts in Duplex, Hastelloy, Inconel, Monel, Stainless Steel, Tantalum, Titanium, Zirconium and coatings in Gold, Rhodium, PFA and PTFE.
Design Comparison: Enhancing Performance Through Intelligent Engineering
Our product range includes designs that address various operational needs:
Low volume capacity
These seals are designed with a reduced fill fluid volume to lower the risk of temperature-induced measurement errors and to minimise potential process contamination.
Backup diaphragm convolution
Seals incorporating a backup diaphragm convolution help the seal maintain its original shape, protecting it from rupturing during overload conditions.
Recessed diaphragm
A recessed diaphragm is less susceptible to installation damage and minimises gasket-induced errors—ensuring a longer lifespan and consistent performance.
High volume capacity
High volume capacity means greater probability of pressure indication errors caused by temperature. Greater process contamination when ruptured.
No backup diaphragm convolution
Leaves the diaphragm vulnerable to rupture should a pressure over load take place.
Protruded diaphragm
Leaves the diaphragm vulnerable to installation damage. Increases chances of gasket induced errors.
Diaphragm Helium Leak Testing.
To ensure the integrity of every diaphragm seal, all our products are subjected to rigorous helium leak testing – up to 10x-10 mbar l/s. This method verifies that no microscopic leaks exist that could lead to fill fluid contamination or compromise the performance of the connected pressure instrument.
Custom Production & Adaptability
Recognising that no two applications are exactly alike, our manufacturing process is highly adaptable. We offer custom production options to meet specific client needs.
- Tailor-Made Solutions:
If your application requires a diaphragm seal with unique dimensions or specialised material properties, our experienced engineers can design and manufacture a custom solution. For example, our Customisable Diaphragm Seals service provides the flexibility to tailor seals to your precise requirements. -
Choosing the Right Size:
Selecting the appropriate seal size is critical to system performance. We provide detailed guidance on Choosing the Right Diaphragm Seal Size to help you achieve optimal pressure transmission and minimise fill fluid volume, thereby reducing temperature-induced errors.
Contact Us Today
If you have any questions about our manufacturing process or need assistance selecting the right diaphragm seal for your application, please call us on +44 (0)1704 509090 or use our online quote request form.
Benefits & Competitive Advantage
Choosing our diaphragm seals offers several distinct advantages:
- Extended Instrument Life:
By protecting sensitive pressure gauges and transmitters from corrosive chemicals and extreme process conditions, our seals help extend the operational life of your instrumentation. - Enhanced Safety:
An all-welded, leak-proof construction ensures that no hazardous chemicals leak into the process or expose personnel to dangerous substances. - Accurate, Reliable Measurements:
Our precision manufacturing and high-quality materials contribute to highly accurate pressure readings, even under challenging conditions. -
Customised Solutions for Every Application:
From standard 316 stainless steel seals to high-performance exotic metal options, our range is designed to meet the diverse needs of industries including pharmaceuticals, petrochemicals, and food processing.
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