Carl,

The component manufacturing design and assembly process is especially critical with UV cure 'seal' materials.  It seems that some organizations get wrapped up in the 'speed' and 'rapidity' of UV cure materials and they don't take the effort to actually study the materials involved.

Generally, these materials have near room temp Tg's, and large CTE's because they are unfilled materials.  I posit that the large CTE is evidenced by the way the 'seal' extruded from the 'seal cavity' in the side views in the first group of images.

Their mechanical properties also are not as mechanically robust as a filled material can be, so even if the materials adhesive properties are sufficient enough, its bulk cohesive, or tensile properties may not...

I argue, that the seal design needs to be more than 'a dollop of glue' ON TOP OF A HOLE.  Your best opportunity to 'seal' with this type of material property is to create a dumb-bell shaped seal where there is a mechanical plug on the inside of the hole as well.  This is likely best accomplished using 'dual cure', or supplemental latent cure materials.

On the other hand, I've known automotive 'quasi-sealed' components that are 'sealed' with a decal of Kapton tape/acrylic adhesive over the vent hole... and that actually worked quite well!

I believe that you are accepting too much responsibility when you say, "failures caused by our assembly process".  Sounds more like a case of false advertising, or exaggerated capabilities.

Happy Spring!

Steve C



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