Failing Ingress Protection Tests | PEM
Why Devices Fail Ingress Protection Tests: Understanding the Weak Points
Manufacturers invest heavily in ingress protection (IP) testing to ensure their products can resist dust, water, and other environmental factors. Yet, not all devices pass these tests—even ones designed to meet strict IP ratings. Failures can result from tiny design flaws, manufacturing inconsistencies, or environmental factors that weaken protection over time.
In this post, we’ll explore the most common reasons why devices fail ingress protection tests, from faulty seals to material degradation, and how these issues can be mitigated.
1. Seal Integrity Issues
The gaskets and seals of an enclosure are its first line of defense against dust and water. If these fail, ingress protection is compromised.
Gasket Material and Wear
- Poor material selection: Some rubber seals work well against water but degrade when exposed to oils, solvents, or extreme temperatures.
- Wear and tear: Over time, gaskets lose elasticity, dry out, or crack, allowing small openings where dust and liquid can enter.
- Compression failure: Over-compressed seals (e.g., from improper assembly) may lose their ability to spring back and form a tight seal.
Misaligned or Improperly Installed Seals
Even a high-quality gasket will fail if misaligned during assembly. A twisted, pinched, or loosely fitted seal can create gaps where contaminants enter, leading to failed water resistance test.
2. Pressure Differentials and Airflow Issues
Enclosures experience internal and external pressure changes that affect their ability to block water and dust.
Vacuum Effect (Suction of Dust or Water)
- If an enclosure is rapidly cooled (e.g., a hot outdoor security camera exposed to sudden rain), the internal air pressure drops. This can suck in moisture through even the smallest openings.
- Sealed enclosures sometimes include breather vents to regulate pressure and prevent this effect.
Hydrostatic Pressure (Submersion Failure)
For waterproof devices (IPX7/IPX8), immersion tests can expose weak spots under increased water pressure. If the device is submerged deeper or for longer than its rating allows, water gradually seeps through seams and weak gaskets.
3. Material and Manufacturing Defects
Even small inconsistencies in materials or assembly can lead to IP test failures.
Corrosion and Degradation
- Metal enclosures may corrode if exposed to moisture and air over time, weakening their ability to stay sealed.
- Plastics can degrade under UV exposure, leading to cracks that allow dust or water ingress.
Manufacturing Tolerances
- If a product’s casing does not fit tightly during assembly, tiny gaps may form where liquid or dust can penetrate.
- Poor welding or fastening in metal enclosures can lead to cracks or weak points.
4. Environmental and Mechanical Stress
Devices used in harsh environments are prone to vibration, impacts, and extreme temperature changes, all of which can weaken their ingress protection.
Impact and Vibration Damage
- Continuous vibration (e.g., in industrial machinery or vehicles) can loosen seals or screws, making enclosures more vulnerable to ingress.
- A dropped smartphone may suffer microscopic cracks or displaced seals, reducing its water resistance—even if it appears intact.
Temperature Fluctuations and Freezing Effects
- Extreme cold can make some materials brittle, causing cracks.
- If moisture gets inside an enclosure and freezes, the expanding ice can break seals or distort the structure.
5. Duration and Repeated Exposure
Even if a product passes an initial ingress protection test, prolonged exposure to dust, water, or extreme conditions can gradually degrade its protective features.
- A phone labeled IP68 may survive a few water splashes but lose its resistance after years of daily exposure to rain or pools.
- Industrial equipment with IP65 water resistance might withstand washing for a year or two, but gaskets will eventually degrade and fail.
Conclusion
Failures in ingress protection often result from small but significant weaknesses—from aging seals to microscopic cracks. Manufacturers take extensive precautions, but real-world usage, environmental conditions, and even wear over time can challenge even the most durable designs.
In the next post, we’ll explore best practices for improving ingress protection in product design and manufacturing.
View our full series of Ingress Protection posts:
How Ingress Protection is Tested