How do you design vehicle sealing systems for weather protection and acoustic performance?

Seal system design involves: Defining environmental protection requirements (water, dust, wind), acoustic transmission loss targets, compression set resistance for durability, closure effort constraints, manufacturing process integration, and material selection (EPDM, TPE). Design uses FEA for compression analysis, CFD for leakage paths, and acoustic simulation for transmission loss. Critical interfaces include door perimeter, window run channels, and body openings. Multi-stage sealing with primary and secondary seals provides redundancy. Validation includes water spray, wind tunnel acoustic testing, and environmental chamber exposure. System must maintain performance over temperature range and aging.