This paper presents a new approach to analytical design of coal mine seals to safely resist explosions during their intended life. Under the current Australian regulations, ventilation control devices (VCD) such as seals and stoppings are required to be tested to achieve pressure ratings of 14, 35, 70, 140 or 345 kPa. Since full-scale testing of seals under various loading regimes is economically prohibitive, a new trend is emerging where high-fidelity physics-based models calibrated using only one full-scale test are employed to predict ultimate strength of seals. In this paper, the explicit dynamics non-linear finite element code LS-DYNA is used to develop high-fidelity physics-based (HFPB) computer simulations to predict the results from physical testing of coal mine seals. Test data from live gas/coal dust deflagration explosions at Lake Lynn, PA, USDA are used to simulate a realistic loading environment caused by 140 kPa (20-psi) explosions. The benefits of the new approach are also outlined.