Finite element analysis has enabled engineers to virtually predict material and product performance, eliminating non-functional possibilities and establishing the best material and design without the cost and time of full-scale production testing. FEA can be used to test an ever-expanding range of materials in new ways by using innovative models. Improvements in the virtual testing process continually come about, resulting in more accurate modeling and confidence on the part of the customer. Simple 2-D models to complex 3-D models can be created, and each has specific applications. Two-dimensional models are typically used for axi-symmetric analysis, allowing engineers to learn how a product will install, grow from thermal expansion, and react to forces applied. Elements of a Successful Model There are several well-established elements in creating a successful model for FEA. 1. A clear and comprehensive plan of boundary conditions such as hardware interaction with the product or seal. How will the product or seal fit into the surrounding hardware? Does it need to be stretched or contorted for installation? Making sure the product or seal is accurately modeled before other parameters are applied is extremely important. 2. A clear and concise understanding of what forces or stresses the product or seal will be subjected to. Will the product or seal be exposed to temperature fluctuations? Will the product or seal be exposed to pressure? What about dynamic movement of the hardware surrounding the product or seal? All conditions the seal will experience must be identified and accounted for in the model. 3. A library of accurately modeled materials, both metallic and non-metallic. We perform almost all of our analysis on non-metallic materials, which require non-linear modeling. This non-linear modeling is dependent upon the quality of the material properties used in the model. Therefore, all materials must be tested in the real world to determine stress-strain curves, Poisson’s ratios, and all physical material properties. It is critical to test the materials at various temperatures, as non-metallic materials have non-linear properties. Having accurately tested material properties will greatly increase the quality of the output data. 4. A robust FEA program. It is crucial to select a testing partner that offers the latest in modern technology and understands how to use it. Flexibility is also crucial to allow for adaptation or a new direction in analysis. 5. A team of analysts representing a range of specialties. No FEA is routine, and a team of experienced people can provide valuable input and ideas to circumvent potential pitfalls. Criteria include a high level of experience in FEA among the team leaders and engineers involved in the design of the product or seal. An FEA analyst may not fully understand the complexity of an application, and product engineers can fill that void.