How To Pass Ingress Protection Tests | PEM
Designing for Ingress Protection: How to Build Reliable and Durable Enclosures
Creating a device with strong ingress protection requires more than just adding seals—it involves careful material selection, precise manufacturing, and smart enclosure design. Whether designing a waterproof smartwatch, an industrial control panel, or an outdoor security camera, engineers must address factors like pressure changes, mechanical stress, and material compatibility.
This post will outline the key design principles for improving ingress protection, ensuring long-term reliability in challenging environments.
1. Choosing the Right Materials
The choice of materials impacts how well a device can resist water, dust, and mechanical wear over time.
Enclosure Materials
- Plastic enclosures (e.g., polycarbonate) offer lightweight protection but may degrade under UV exposure.
- Aluminum or stainless steel provides excellent durability and corrosion resistance for industrial applications.
- Coated metals can improve resistance to chemicals, salt, and moisture.
Seal and Gasket Materials
- Silicone: High flexibility, good for waterproofing at various temperatures.
- EPDM (Ethylene Propylene Diene Monomer rubber): Resistant to heat, cold, and UV exposure.
- Nitrile rubber: Ideal for oil-resistant seals in automotive and industrial settings.
2. Smart Enclosure Design
An enclosure’s design should minimize weak points where dust and liquids can enter.
Minimizing Seams and Openings
- Reducing the number of seams and joints helps eliminate potential failure points.
- Components should be tightly fitted to prevent unintended gaps.
Overlapping Joints and Double-Seal Mechanisms
- Raised edges or double-lip seals add extra barriers against liquid ingress.
- Interlocking parts can create a labyrinth effect, making it harder for dust and water to reach critical components.
3. Accounting for Pressure and Venting
Devices subjected to pressure changes (e.g., underwater electronics, industrial enclosures) require pressure equalization strategies.
Using Breather Vents
- Special membrane vents allow air to pass while keeping water and dust out.
- This prevents vacuum effects that might draw in moisture.
4. Testing and Validation
Once a device is designed, rigorous testing ensures it meets its IP rating requirements.
- Simulated real-world testing beyond standard IP tests can highlight unexpected failure points.
- Long-term durability tests assess how materials degrade over time.
Conclusion
Designing for ingress protection is a multifaceted process, requiring the right materials, structural design, and testing protocols. By understanding how environmental factors impact device performance, engineers can build enclosures that truly stand the test of time.
To be confident that your enclosures will pass the Ingress Protection test, you must understand why the choice of fastener matters.
View our full series of Ingress Protection posts:
How Ingress Protection is Tested