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I'm designing a custom part that needs an active shock absorber and space is restricted. I most likely won't be able to use a stock absorber and was thinking, can two squarish tubes be made tight enough?

akauppi
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Assuming reasonable pressures, it should be workable.

However, keep in mind that the pressures will be higher at the corners and you'll run a higher risk of leakage / bursting. Cylindrical tubes distribute the pressure evenly across the bearing surface and don't have that issue.

You'll also potentially have difficulty with fabricating a gasket to seal the space between the square tubes.

Given the minimal difference in surface area between a cylindrical and square tube, and the ready prevalence of cylindrical tubes, it does beg the question as to why you feel a square tube is the more appropriate design choice.