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Making electronics waterproof

Published: 27 October 2024
Last updated: 29 October 2024

Intro

Waterproofing electronics requires more than just using a waterproof enclosure, as condensation often forms within the housing. Below, I discuss my experiences and methods for effectively protecting electronics from moisture, including PCB protection, housing sealing, and using pressure balance elements to prevent internal condensation.

1. Waterproofing the PCB

Kafuter K-705 clear silicone rubber RTV Adhesive: My experience has been very positive. It’s easy to apply with a piece of paper, allowing it to spread evenly while avoiding connectors. Additionally, the tube doesn’t dry out over time, unlike other silicone products.

Silicone-waterproof-conformal-PCB-coating.JPGKafuter K-705 silicone waterproof conformal coating for PCB

Kontakt Chemie Plastic 70: Although this spray is commonly used, it performs poorly. The coating shrinks, leaving the tops of SMD components unprotected. To achieve proper water protection, you need to apply at least five thick layers. Additionally, it’s challenging to keep connectors free of coating during spraying.

2. Waterproofing the electronics enclosure

For testing, I used an aluminum enclosure from an e-bike motor controller. I wanted to test if a very narrow 1mm gasket would be effective. I tested with Superhelp Black Silicone Gasket Maker and left the enclosure outdoors in all weather conditions for one year. The result was positive: the enclosure remained completely waterproof throughout the year.

IP67 waterproof electronic enclosure2IP67 waterproof electronic enclosureIP67 waterproof electronic enclosure1IP67 waterproof electronic enclosure
OLYMPUS DIGITAL CAMERA         Waterproofing electronic enclosure with silicone gasket.JPG

3. Pressure balance element

Condensation inside sealed enclosures is inevitable due to temperature fluctuations. To manage this, I use a self-adhesive IP67 waterproof venting membrane. This allows moisture to escape from the enclosure but prevents moisture from entering.

IP67 self adhesive waterproof venting membraneIP67 self adhesive waterproof venting membrane

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