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Waterproofing is a Lie: Real-World IP67/IP68 Enclosure Design That Works

1. What IP67/IP68 Actually Mean—and Why They Often Fail in the Field

Before we dive into design, let’s get clear on what IP67 and IP68 actually mean.

• IP67: Dust-tight and protected against the effects of immersion in water up to 1 meter for 30 minutes.
• IP68: Dust-tight and protected against long-term immersion in water beyond 1 meter (typically specified by the manufacturer, but often up to 3 meters or more).

This rating refers to a combination of tests, including dust protection and water immersion, so your design must account for both factors. However, it's important to understand that these ratings are lab tests under controlled conditions. What happens in the real world? Water ingress can still occur, especially if you haven’t designed with the specifics of these ratings in mind.

Key takeaway: IP ratings are based on lab conditions, and the actual waterproofing performance is highly dependent on material choices, sealing methods, and environmental factors.

2. Why Gaskets Alone Won’t Protect Your IP-Rated Device

Let’s start with the most obvious feature: seals. Too often, engineers rely solely on rubber gaskets or O-rings to keep water out. While these components are critical, they aren’t foolproof. The wrong material, improper installation, or inadequate compression can lead to leaks that render the enclosure useless in real-world conditions.

In one example, a field-deployed GPS unit with an IP67 rating failed after only a few months in the field. The culprit? A poorly designed seal that allowed water to slowly seep in, damaging sensitive internal electronics.

Key design tips:

• Select seals based on compression set properties and material resistance to water and UV degradation.
• Ensure proper sealing around cable entries, buttons, and connectors, which are often overlooked in basic designs.
• Avoid relying on a single gasket; multiple overlapping seals can provide better protection.

3. How Temperature, Pressure & Vibration Break Waterproof Designs

An IP67-rated device may pass static water immersion tests in a controlled environment, but what happens when it’s exposed to temperature fluctuations, pressure changes, or vibration? These dynamic factors can compromise the integrity of your enclosure over time.

One of the most common failure modes we’ve seen involves electronics that are deployed in outdoor or industrial settings, where thermal expansion can break the seal or allow condensation to form inside the enclosure. We’ve worked with a client that suffered repeated failures of their IP68-rated enclosures because temperature swings caused the gaskets to contract, leaving small gaps for water to enter.

Key design tips:

• Use high-temperature resistant seals that can handle thermal cycling.
• Include ventilation with a breathable membrane to allow for pressure equalization without compromising IP rating.
• Test your enclosure design across a wide range of operating conditions, including humidity and fluctuating temperatures.

4. Why Venting Is Critical for IP67/IP68 Enclosure Reliability

Many engineers overlook venting, but it’s one of the most critical factors when designing an IP67/IP68 enclosure. Vents allow the enclosure to handle pressure changes during operation (such as altitude shifts or thermal cycling), and prevent damage to seals or enclosures due to vacuum pressure differentials.

We’ve worked with clients who faced ongoing issues with water ingress in their outdoor power electronics units, only to find that lack of proper venting was the primary cause. In one case, the product passed initial testing but failed after being deployed at a remote location where extreme temperature fluctuations caused internal pressure changes. Without a vent, the seals would occasionally pop or leak.

Key design tips:

• Integrate venting membranes with hydrophobic properties to prevent water ingress while allowing pressure equalization.
• Position vents away from areas where water or dust could easily be forced into the enclosure.
• Use a filtering vent to prevent moisture or dust from entering the enclosure during sudden atmospheric pressure changes.

5. The #1 Cause of Waterproofing Failure: Connectors and Cables

The connectors, cables, and ports that enter your enclosure are often the first places to fail, even on highly rated enclosures. In particular, designs that use standard connectors with inadequate sealing are prone to water ingress, especially when exposed to high-pressure water or immersion.

We’ve seen several cases where IP67-rated enclosures failed due to water creeping in through unsealed connectors. The issue typically stems from a lack of thought given to the actual installation and long-term exposure of the product to high-pressure water (such as underwater or pressure-washing environments).

Key design tips:

• Use IP-rated connectors that are specifically designed for harsh environments.
• For high-pressure environments, consider using screw-lock connectors with seals or compression fittings.
• Ensure cable entries are properly sealed with cable glands that match the diameter of the cables passing through them.

Conclusion

Designing for IP67 and IP68 enclosures isn’t just about checking a box on a spec sheet. Achieving true water protection involves understanding the limitations of seals, the effects of environmental conditions, and how real-world usage can introduce dynamic stressors to your design. It’s a multidisciplinary challenge that requires thoughtful attention to detail across all components of your enclosure.

At SOENCO, we specialize in engineering solutions that go beyond the basics. Whether you need to meet IP67/IP68 requirements for rugged consumer devices or high-performance industrial equipment, we can help you design enclosures that truly perform in the real world.

Let’s design for durability, not just compliance.

Contact us today to discuss your enclosure design and ensure it holds up in any environment.