How Ingress Protection is Tested | PEM
How Ingress Protection is Tested: Ensuring Reliability in Harsh Environments
A smartphone labeled IP68, an industrial machine rated IP65, or a smartwatch with IPX7—these numbers provide confidence that devices can withstand dust, water, or both. But how do manufacturers ensure these claims hold up in real-world conditions? The answer lies in rigorous ingress protection (IP) testing.
Testing methods simulate real-life environments, ensuring that devices perform as expected, whether exposed to fine dust, rain, water jets, or even full submersion. In this post, we’ll explore the key testing procedures that determine an IP rating, including solid particle testing and water ingress testing.
Testing for Solid Object and Dust Protection
Devices with an IP rating that includes a first digit (1-6) undergo solid object testing to evaluate their ability to block dust, debris, and foreign objects. The higher the number, the more resistant the enclosure is to particles.
Dust Chamber Testing (IP5X & IP6X)
For products claiming dust resistance, a dust chamber is used. The device is placed in a sealed chamber filled with fine talcum powder or other small particles, with a controlled airflow simulating real-world conditions.
- IP5X: Some dust may enter, but not enough to interfere with function.
- IP6X: Completely dust-tight; no particles can penetrate the enclosure.
To enhance the test's accuracy, some enclosures are subjected to a vacuum effect, mimicking scenarios where pressure differences might pull dust inside.
Solid Object Penetration Tests (IP1X to IP4X)
These tests check if objects of different sizes can penetrate an enclosure:
- IP1X: Protection against large objects (e.g., a hand).
- IP2X: Protection against fingers.
- IP3X: Protection against tools and wires larger than 2.5mm.
- IP4X: Protection against fine tools and small objects larger than 1mm.
A testing probe of a specific size and shape is used to attempt to reach internal components. If it cannot make contact, the enclosure meets the required standard.
Testing for Water Ingress Protection
For devices claiming water resistance (IPX1-IPX9K), a series of tests expose enclosures to controlled amounts of water under varying conditions.
Drip Testing (IPX1 & IPX2)
Simulating rain or light condensation, this test involves dripping water onto the device from a height of 200mm for 10 minutes.
- IPX1: Water drips vertically onto the enclosure.
- IPX2: The device is tilted at a 15-degree angle, and the test is repeated to simulate different orientations.
Spray and Splash Testing (IPX3 & IPX4)
Devices designed for outdoor or kitchen environments must handle water splashes from different angles.
- IPX3: Water is sprayed up to a 60-degree angle from vertical using a specialized nozzle or oscillating tube.
- IPX4: Water is sprayed from all directions, simulating rain or splashing.
For IPX4, the device is often rotated during testing to ensure complete exposure.
Water Jet Testing (IPX5 & IPX6)
Higher levels of protection require resistance to water jets, simulating conditions such as washing or exposure to strong rain.
- IPX5: Water jets from a 6.3mm nozzle at 30 kPa pressure from all directions.
- IPX6: More intense water jets from a 12.5mm nozzle at 100 kPa pressure.
This test ensures that the device remains operational even when exposed to water from a hose or high-pressure cleaning.
Immersion Testing (IPX7 & IPX8)
For products like waterproof smartphones and underwater cameras, immersion tests are conducted.
- IPX7: Submerged in 1 meter of water for 30 minutes.
- IPX8: Submerged deeper than 1 meter, with the exact depth and time set by the manufacturer.
After testing, the device is examined for water ingress. If moisture reaches critical internal components, it fails the test.
High-Pressure, High-Temperature Jet Testing (IPX9K)
Used for automotive and industrial equipment, IPX9K testing involves high-temperature water jets blasted at the enclosure. The test simulates extreme cleaning conditions, such as pressure washing.
- Water is heated to 80°C
- High-pressure jets (up to 100 bar) spray from multiple angles
- Rotation ensures full exposure
Only the toughest enclosures, such as those used in military and automotive applications, pass this test.
Ensuring Accuracy and Reliability
IP testing follows ISO 20653-2014 and IEC 60529 standards to maintain consistency across industries. Some manufacturers go beyond these tests, using real-world simulations such as dropping waterproof phones in pools or exposing industrial equipment to extreme dust storms.
Conclusion
IP testing ensures that enclosures live up to their protection claims, giving consumers and businesses confidence in a product’s durability. From dust chambers to water immersion tanks, these rigorous procedures help verify resistance to environmental hazards.
In the next blog post, we’ll discuss why some devices fail water resistance tests and explore the factors that influence whether liquids leak into enclosures.
View our full series of Ingress Protection posts:
Failing Ingress Protection Tests