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O-ring seal design for removable marine sensor housing

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Hi! My project is a small-scale marine sensor housing; it needs to stay functional when briefly submerged (around 0.5 m depth) or exposed to heavy splashes on a boat deck. I’m using a machined aluminum cylindrical base and a clear polycarbonate cover — both have the same diameter (95 mm). The cover should be easy to remove for battery swaps, but I still need to keep a reliable seal when closed. Any advice on an effective O-ring groove design or alternative sealing approach that would allow repeated opening without losing waterproof integrity?

    • H

      Hi! My project is a small-scale marine sensor housing; it needs to stay functional when briefly submerged (around 0.5 m depth) or exposed to heavy splashes on a boat deck. I’m using a machined aluminum cylindrical base and a clear polycarbonate cover — both have the same diameter (95 mm). The cover should be easy to remove for battery swaps, but I still need to keep a reliable seal when closed. Any advice on an effective O-ring groove design or alternative sealing approach that would allow repeated opening without losing waterproof integrity?

      0
O-ring seal design for removable marine sensor housing
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