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Case Study: Innovative Oval-Shaped Plug for Defence Application


Welcome to AFAC Custom Moulding Division! Today, we are excited to present an innovative oval-shaped plug designed for a defence application. This case study highlights the creation and long-term success of a custom solution developed to address the specific needs of masking electrical contacts during powder coating or high-temperature metal finishing.

The Challenge

Over 25 years ago, our client in the defence sector faced a significant challenge: effectively masking an oval slot hole and its surrounding area during the powder coating process. The primary issue was ensuring a perfect seal to prevent powder from creeping under the plug, which could compromise the integrity of the electrical contacts and the overall quality of the finished product.

Our Solution

AFAC developed a custom oval-shaped plug specifically designed to address this challenge. Here are the key features of our solution:

  1. Oval Shape: The unique oval shape of the plug was tailored to fit the specific dimensions of the slot hole, ensuring comprehensive coverage.
  2. Protective Ring: The plug features a protective ring around its base, providing a perfect seal and preventing any powder from seeping underneath during the coating process.
  3. High-Temperature Resistance: Made from durable materials, the plug can withstand the high temperatures involved in powder coating and metal finishing processes, ensuring reliable performance and longevity.

Implementation and Results

The custom oval-shaped plug was integrated into the client’s manufacturing process and has been a crucial part of their production ever since. Here’s how it made an impact:

  • Effective Masking: The plug provided an effective solution for masking the oval slot hole and its surrounding area, ensuring that the electrical contacts remained free from powder.
  • Perfect Seal: The protective ring feature ensured a liquid-tight seal, maintaining the integrity of the masking and preventing any powder from creeping under the plug.
  • Durability and Reliability: The high-temperature resistance of the plug ensured that it could withstand repeated use in the demanding conditions of the client’s manufacturing process, providing long-term reliability and performance.

Client Feedback

The client has continued to use the custom oval-shaped plug for over 25 years, a testament to its effectiveness and durability. They have praised the plug’s ability to provide a perfect seal and maintain the quality of their finished products. The consistent performance of the plug has made it an indispensable part of their production process.


This case study highlights AFAC’s expertise in developing long-lasting, effective custom solutions for challenging industrial applications. The innovative oval-shaped plug designed for the defence sector demonstrates our commitment to addressing specific customer needs and ensuring high-quality results.

If you are a quality manager, production manager, or product designer looking for custom masking solutions that meet precise requirements, AFAC is here to help. Contact us today to discuss your needs and discover how our bespoke products can enhance your manufacturing processes.

Get in Touch

For more information on our full range of capabilities, please complete the form below or contact our team directly on 0345 094 0993. At AFAC, we’re committed to pushing the boundaries of what’s possible with silicone rubber mouldings.

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