Abstract: A kind of aluminum honeycomb seals which would hardly make friction sparks was explored.The ANSYS and CFX software were used to determine the minimum wall thickness of this honeycomb seals,and to study how the single change of wall thickness and how the joint change of wall thickness,honeycomb opposite edges distance and honeycomb depth influenced its sealing performance.Meanwhile,analysis from the perspective of sealing pressure drop explained why the difference of those parameters above would cause the changing of aluminum honeycomb seals’ leakage.Results show that the wall thickness of aluminum honeycomb seals shouldn’t be less than 0.5mm;the leakage of aluminum honeycomb seals increase with the wall thickness increasing,since its pressure drop minish with it.The results also show that different optimal ratios of honeycomb depth and honeycomb opposite edges distance are suitable for the aluminum honeycomb seals with different wall thicknesses,aiming at reducing their leakage to minimum.Two specifications aluminum honeycomb seals were designed and produced.