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Expandable cavity sealers have become a critical component of the overall acoustic package that contributes to the documented noise reduction in passenger car applications over the course of the last twenty years. They encompass a variety of technologies, some of which are delivered into the supply chain as bulk materials and others which are highly engineered parts and assemblies. As the market for smaller and more fuel efficient vehicles continues to expand, design architectures of the base vehicle platforms are evolving to include body designs with smaller spaces between adjacent layers of sheet metal. As this space, or cavity, between the adjacent layers of sheet metal is shrinking, the complexity of components that must be integrated into the space between these layers of steel is increasing. Complex arrays of airbags, corresponding wire harnesses, and water management tools are now standard requirements in the design process.