Electrifi™ EMI Connector Gasket

Overview

The Electrifi™ EMI Connector Gasket is a 3D printed conductive interface designed to provide electrical continuity and electromagnetic shielding at connector and panel junctions.

Unlike traditional EMI connector gaskets that rely on conductive silicone elastomers, conductive fillers, or fabric-over-foam constructions, the Electrifi™ gasket is fabricated using a high-conductivity copper composite material that delivers bulk electrical conductivity throughout the structure.

This enables rapid customization, low-volume production, and geometry-specific shielding solutions without tooling or molded silicone processes.

This product is offered as an engineering sample under the Electrifi™ Functional Prototype Validation Program.

Functional Purpose

Connector interfaces are common leakage points in EMI-sensitive systems. The Electrifi™ EMI Connector Gasket is designed to:

• Maintain electrical continuity between connector flange and chassis

• Reduce radiated emissions leakage at panel cutouts

• Improve grounding reliability

• Support compliance testing during early-stage prototyping

Key Features

• Bulk conductive composite material

• Customizable geometry for specific connector footprints

• Rapid fabrication without tooling

• Suitable for low-to-medium compression interfaces

• Designed for EMI shielding validation and prototyping

• Direct integration into additive manufacturing workflows

Physical & Fabrication Specifications

The structure is printed fully solid to maximize electrical continuity and mechanical integrity.

Comparison to Traditional Conductive Silicone Gaskets

Conventional connector gaskets typically use:

• Conductive silicone elastomers

• Silver- or nickel-filled silicone

• Fabric-over-foam structures

• Die-cut conductive sheets

These methods require:

• Mold tooling

• Secondary fabrication processes

• Inventory of standard shapes

• Longer development cycles

Electrifi™ enables:

• Tool-free production

• Rapid geometry iteration

• Custom flange and connector cutout matching

• On-demand manufacturing

• Integrated conductive structure without coating

Applications

• Panel-mount connector shielding

• RF connector interfaces

• Embedded system enclosures

• Industrial control panels

• Aerospace and defense prototyping

• EMI troubleshooting and mitigation testing

Design Characteristics

Electrifi™ EMI Connector Gaskets can be fabricated in:

• Flat compression profiles

• Raised sealing ribs

• Custom flange geometries

• Multi-bolt hole patterns

• Integrated conductive grounding tabs

Designs can be optimized for:

• Contact surface area

• Mechanical compliance

• Electrical continuity

• Assembly torque requirements

Engineering Validation Component

Participants are encouraged to evaluate:

• Contact resistance

• Compression behavior

• Shielding effectiveness (SE in dB)

• Frequency-dependent attenuation

• Long-term contact stability

Submitted validation data may qualify for store credit under the Electrifi™ Functional Prototype Validation Program.

Why Electrifi™ for EMI Interfaces?

Electrifi™ conductive composite enables:

• High electrical conductivity compared to typical conductive polymers

• Uniform conductivity throughout the gasket volume

• Rapid customization without molds

• Direct digital workflow from CAD to functional part

This makes Electrifi™ EMI Connector Gaskets particularly suitable for:

• Prototype validation

• Low-volume production

• Custom connector footprints

• Rapid EMC troubleshooting