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Abstract: A methodology to design an air-lubricated piston seal for pneumatic actuators is described. Such a seal permits a small air leakage through a very narrow gap between the seal lip and the counterpart; this air film both avoids contact and ensures lubrication at the seal-counterpart interface thus permitting reduced friction and wear. Subsequently the use of grease could be limited or avoided. A seal geometry equipped with a self-pressurized balancing chamber was designed to make leakage as insensitive as possible to the supply pressure and to the barrel machining tolerances. A prototype was manufactured and tests were carried out. [Copyright &y& Elsevier]