O-Ring Groove Generator creates fully dimensioned O-ring grooves right on your model — in seconds instead of catalog-and-calculator minutes.

Shaft first — the way engineers actually work
Pick one circular edge on a shaft shoulder or bore and you are done: the add-in measures the diameter, detects shaft vs. bore (piston vs. rod groove) automatically and suggests matching standard O-rings, best fit first. Matching is done correctly at the seat: piston grooves match the ring to the groove bottom (target ≈ 2 % stretch), rod grooves to the rod (≈ 1 %). Seat diameter and stretch are shown in every suggestion.

Four seal types
• Piston groove (radial, groove on shaft/piston)
• Rod groove (radial, groove in the bore)
• Axial groove, internal pressure
• Axial groove, external pressure/vacuum

New in v1.10: design by cord diameter
• Target compression depends on the cord diameter d2 — thin cords are compressed more, thick cords less. Static radial: 26 % (d2 ≤ 2 mm), 20 % (up to 4 mm), 19 % (up to 5.5 mm), 17.5 % (above). Dynamic: 19 % (d2 ≤ 2 mm) or 13 %. Axial: 25 %, from d2 = 5 mm 23 %. Target fill 75 %, 70 % for d2 > 6 mm. Checked against the Parker groove tables.
• Dynamic grooves get the same width as static ones.
• The result field lists the manufacturing tolerances of groove width b and depth t (+0.2/+0.05 mm up to d2 = 3 mm, +0.25/+0.1 mm above).
• If the ring is fitted stretched, the report shows the effective compression with the reduced cord diameter.

Transparent and overridable
Groove depth, width, bottom and edge radii, squeeze, gap and fill ratio are reported live in the dialog, including warnings (fill too high, groove too close to the edge, thin web). Manufacturing hints included: tolerance recommendations (groove bottom h11, bore H8) and Ra values. Company standards? Override any value manually.

Tidy timeline, intuitive control
The groove appears as ONE named item ("O-ring groove d1×d2") in the timeline. The offset from the reference edge has a draggable arrow in the model (like Extrude); "flip direction" puts the groove on the other side.

Thinks along
• Chamfers and fillets on the reference edge are skipped automatically — the cylinder behind becomes the groove carrier.
• Works in nested, transformed components.
• Optionally creates the O-ring as a body: nominal (torus) or installed-deformed with a volume-true profile, rubber material applied for correct display and mass.
• Verified catalog of 1814 sizes: AS568 / ISO 3601-1 class A (349, three sources), ISO 3601-1 class B / DIN 3771 (374, two sources) and metric dealer stock sizes (1091; sizes backed by only one dealer are marked with * in the dropdown). Any custom size manually.
• Fully bilingual EN/DE, following the Fusion UI language.

Who is it for?
Mechanical design engineers, jig/fixture and prototype builders, hydraulics/pneumatics, training — wherever O-ring grooves recur and should look consistent across the team.

Note
All values are guideline values for standard applications based on ISO 3601 methodology and manufacturer practice. For high pressure, temperature extremes, swelling media or safety-critical parts, consult the manufacturer catalog and ISO 3601-2; responsibility remains with the engineer.