Waterproof Enclosure Design: Everything You Need to Know

Electronics of various types require waterproofing because if water seeps inside them, disruptions could occur. Hence, manufacturing waterproof enclosures for various applications is quite common.

If you are interested in learning about waterproof enclosure design and related matters, the guide below can help you. So, let's read.

The International Protection (IP) Marking System

IP stands for International Protection Marking System, which helps to evaluate the housing of electronics. This is also known as ingress protection marking and is associated with the waterproof tests having different levels.

It has a set of two numbers; the first number identifies the dust-proofness, and the second number identifies the waterproofness.

Decoding the IP Code

The IP code is written as IP and has two numbers. The numbers for the first digit represent association with solids having a range of 0 to 6. It represents the levels of dust particles.

The second digit is associated with the liquids and has a range of 0 to 9, which represents protection against water.

What Does the Ratings Mean?

The first digit for dust protection has a range of 0 to 6, where each number represents the level of protection.

• 0: Means no protection.
• 1-2: This means protection against particles that are more than 50 mm in size.
• 3-4: Means protection against dust particles larger than 2.5 mm.
• 5: It means that the dust can get in, but it won't impact the functionality.
• 6: It represents a 100% dust-tight enclosure.

The second-digit protection is as follows:

• 0: No protection
• 1: Protection against water droplets falling vertically
• 2: Protection against water droplets from an angle of 15 degrees.
• 3-4: Protection against splashes and sprays of water
• 5-6: Protection against heavy seas
• 7-8: Protection against water immersion for a depth of a maximum of 1 meter.

The NEMA Rating System

The NEMA rating system stands for National Electrical Manufacturer Association, and it provides insight into how much a product is protected.

It mostly applies to industrial products. NEMA rating systems go beyond the protection of water and dust. It works by exposing products to corrosives, ice, and oil.

The NEMA rating system is analyzed based on the product used indoors and outdoors. The comments used indoors have a rating of 1-13 and show protection from electrical shock and dust.

The outdoor ratings for NEMA are 3R, 3, and 3S. NEMA 4 is suitable for enclosures which are subjected to high water pressure.

Designing Functional Seals

There are different designs of water seals that can be created, and some of these are as follows:

Static O-ring Seals

When you need a seal design for circular products you can use the static O-ring seal. These seals do not let the mating gland parts move and hence the sealing surface has no movement.

Dynamic O-ring Seal

Dynamic o-ring seals have movement on their mating gland parts, and hence more lubrication is needed by the material. The material must also be stronger than the one opted for manufacturing static o-rings.

Gasket Design

A gasket is a type of sealant that works as a plaster, glue, or spray and holds the joints together. These can be used with and without various other sealants. These are suitable for face-to-face seals and have multiple cavities.

A Note on Compression Set

One of the problems associated with rubber seals is that they can take the shape of the material for which they are used. It makes them lose their shape, and hence, the right material is important to them.

Buttons

Buttons are used in panel switches, triggers, and directional pads and are suitable sealants for those who want to deal with interfacing issues. They are easy to install and affordable.

Buttons are manufactured using different materials. The low-pressure design of waterproof buttons uses rubber buttons, and the heavy-duty buttons use harder materials.

Material Selection in Waterproof Enclosure Projects

The selection of materials in waterproof enclosures requires considering certain factors, and these are as follows:

Factors to Consider in Material Selection

Development Stage

The development stage determines the material you use, and for this, you will have to go different stages. For instance, the prototype development stage material, which is cheap, is suitable.

You do not need to worry about the effectiveness of waterproofing, and you just need to test the design.

Design Guide and Use

The design guide that you use in the process of manufacturing the product predicts the material type to be chosen. For instance, the enclosure design, which is high-pressure, will need CNC machine-compatible materials.

Durability of Enclosure

The durability of the material is associated with the environment it is subjected to. For environments that need durable waterproof enclosures, relevant materials must be chosen.

Common Materials Used for Waterproof Enclosure

The common materials used for waterproof enclosures are the following:

Kunststoffe

Kunststoffe are versatile, and they are very commonly opted for waterproof enclosures as they are resistant to corrosion. They are, however, not as strong as metal enclosures.

Metalle

The waterproof enclosures are made using metals composed of Aluminium, stainless steel and steel.

• Steel: It is used in circumstances where the tendency of corrosion is less, hence it is suitable for environments which have less chance of corrosion. It is also very durable and strong– hence makes enclosures resistant to scratch.
• Aluminum: Aluminum is suitable for enclosures that need saltwater stability. It offers corrosion resistance. It is also lightweight and suitable for alkali-based environments.
• Stainless steel: Stainless steel enclosures are durable and corrosion-resistant.

Recommendations for Waterproof Prototyping

The process of designing a housing uses lower-resolution materials to achieve the right fit, aesthetics and functions of the design; it helps test waterproof capability.

3D printed PLA is a suitable process to first gain insight into the look of the enclosure. It helps to test the interface of the part, which uses materials like nylon or 3D-printed ABS.

The plastic materials used for printing enclosures are highly accurate, and it leads to a high-quality seal.

For high-pressure seals, you will have to consider a CNC machining prototype. It ensures that the quality of the surface is excellent and the prototype is highly accurate and tight tolerant.

What Surface Finishes can be Used for Waterproof Housings?

The selection of the type of surface finishing for the waterproof housing is dependent on the type of material it is made of.

However, the two most commonly opted types of surface finishing choices are discussed below:

Eloxieren

Eloxieren can be of different types, such as sulphuric acid anodizing, hard anodizing, and chromic acid anodizing. They give a layer of corrosion resistance to the aluminum-based enclosures.

Moreover, anodizing also improves the electrical insulation, heat resistance, adhesion and bond strength.

Pulverbeschichtung

Pulverbeschichtung is a surface finishing process that adds a protective layer to the stainless steel. The dry powder is fused on the metal surface with an electric charge, and the coated enclosure is then left for curing to help achieve a final finish.

Powder coating makes stainless steel highly resistant to corrosion and also adds a layer of thickness that enhances the tolerance of the enclosure.

Tips for Waterproof Enclosure Design

The tips for waterproof enclosure, which you must keep in mind, are as follows:

• You may wish to seal the enclosure completely, but it is not a suitable approach to seal the enclosure completely. If you seal the enclosure completely, it will be difficult for the air vapor to get in and out of the enclosure.
• The circular enclosures are suitable for having waterproof coverings. These are very easy to use and affordable.
• Complex seals must be avoided; the components which are sealed together must not be more than three components.
• When you use a gasket you have to add support on all the sides. In case you do not add support, you can have a failed seal as the gasket pulls out of the pinch zone.

Schlussfolgerung

Waterproof enclosure design requires considering all the important aspects like materials, designs etc.

You can contact us at DEK. We provide you with waterproof enclosures of high quality and precision. We have trained and experienced professionals and engineers with advanced machines to help you manufacture custom enclosures.

FAQs

How do you make a waterproof enclosure?

There are different ways to manufacture waterproof enclosures, such as o-rings and gaskets. They are manufactured through processes like injection moulding.

What IP rating is weatherproof?

IP rating which is weatherproof consists of IP66, IP67, IP65. These enclosures offer protection against high moisture.

Can you make a waterproof plastic prototype enclosure?

Yes, different types of plastic can be chosen to make waterproof enclosures, and rubber seals are also very popular.

Can you provide waterproofness testing?

Yes, by placing the enclosure under the water column, you can test its waterproofness.