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Metallic gasket components are used in diverse automotive gasket applications. The use of a non-linear finite element (FE) code has allowed the analysis of both the manufacturing process and the subsequent gasket performance. The manufacturing analysis determines the best tool geometry to be used with the chosen material. Component geometry and its internal stresses and strains are optimised. The performance analysis ensures a functional, robust gasket, with a reduction in development time. The evolution of surface pressures, as a function of either applied load or compressed thickness, can be supplied to engine models for subsequent engine structure distortion studies.