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Thanks for the responses. dgallup: zero leakage, continuously for years, its in an indoor environment, 10's of thousands. I don't agreed about an elastomer being essential - there are many different ways to seal electrical contacts e.g. for high pressure vessels (1000 + bar) which don't involve...

It could work if I'm understanding your suggestion correctly. We will be getting the pin manufactured so can make it however we like. Has anyone got any experience with interference fitting metal into plastic for a liquid seal?

I guess you mean something like this: The main issue is that pin is 1mm diameter. And thats quite a lot of parts if just an interference fit or insert mold will do the same job? fluid is mainly water but sometimes a slightly alkaline cleaning solution. Its used in a water dispensing system...

Thanks for the response. Yep - we have experimented with this we used Loctite 770 as a primer and then 403 (rather than epoxy) for the fillet - both are approved for potable water. Why would you go for Option (3) instead of Option (2)? Is Option (3) an accepted thing to do? Thanks!

Some smart guys in here [thumbsup2] Was hoping for some advice - need to seal a stainless 316 pin (for electrical measurement) against 10 bar fluid pressure in plastic injection molded part (food safe e.g. PP). See rubbish sketch I made with a few ideas. Pros and cons: Option 1: insert molded...