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This paper describes a joint development and testing program between Tier I suppliers and a North American automotive company to determine the efficacy of a new generation of cure-in-place gasketing materials (CIPG) as flange seals for water pumps. Employing a systems approach to validate design and process test procedures, the program demonstrated that this chemically-based material provides superior performance in applications requiring resistance to powertrain fluids. When combined with proper flange design, process controls, and dispensing systems, it proved robust and economical. Compared to the sealing methods and material it replaced, the new CIPG compound delivers improved processing, manufacturing flexibility, and enhanced quality.