IP67 vs. IP68: Which Waterproof Rating Suits Your Application Better?

"IP67 and IP68 sound waterproof, but why is there such a big difference in the price? Which one should I choose?" Of course, the bigger the number, the better. The most important thing is the right one. This article is a professional perspective from Unionwell, a micro switch manufacturer. It uses the most popular language to dismantle the differences and choices between IP67 and IP68 to help manufacturers and buyers spend their money wisely.

What Is IP Protection Level? Basic Knowledge That Manufacturers Must Master

Standards And Definitions Of IP Protection Level

IP level is defined by IEC 60529 standard, and the first and second digits represent "dustproof capability" and "waterproof capability" respectively. The first digit is between 0 and 6 (the larger the number, the better the seal), 6 means completely dustproof, which means that the micro switch housing has zero penetration of particles larger than 75 µm; the second digit is between 0 and 8 (the larger the number, the better the seal), and 7 or 8 describes its underwater survival time and depth. Compared with the marketing terms "waterproof" and "three-proof", the IP code has a quantifiable and repeatable test method, which is widely cited in the global certification system.

IP67 And IP68 Micro Switch Protection Capabilities

IP67 means that the device can still operate normally after being placed in 1 m water depth for 30 minutes; IP68 requires the manufacturer to indicate a more stringent "depth + time" combination in the certification report, such as 2 m/60 min or 5 m/30 min, and only after the test is passed can it be marked IP68. On the surface, it is just a number difference of 1, but the test standard of IP68 is much stricter than that of IP67, and the protection capability is also better.

Detailed Explanation Of IP67 And IP68 Definitions

IP67: Short-Term Immersion In Water

IP67 micro switches are stable in the spray environment of the vehicle body, engine compartment or production line. The test conditions are 1 m deep static water for 30 minutes, and the pressure value is about 0.1 bar. This level has covered most of the actual humid working conditions, such as door lock position detection, wiper return detection, outdoor rainy working conditions, etc.

IP68: Long-term Immersion

According to the definition of protection level (IP code) in the International Electrotechnical Commission standard IEC 60529, IP68 is one of the highest levels of waterproof performance. Unlike the "1 meter water depth, 30 minutes" standard of IP67, IP68 does not have a fixed test depth and time. The key point is that the manufacturer independently specifies the depth and time used for long-term immersion testing based on product design (such as 2 meters water depth, immersion for 1 hour or 72 hours, etc.). Note: IP68 does not mean that it can be waterproof for "unlimited time and unlimited depth". You still need to refer to the specific product technical specifications.

Differences In The Structure Of IP67 And IP68 Waterproof Micro Switches

"Invisible Upgrade" Of Sealing Technology

IP67 models usually use elastic Oring with plastic sealing base, and the waterproof structure only covers the drive handle and terminal lead-out area; while IP68 requires double-layer silicone potting inside the terminal, and balances the air pressure through Gore breathable membrane to avoid negative pressure water absorption caused by temperature drift. The thickness of the seal is increased by at least 30%, and epoxy-modified silicone must be used to take into account both salt spray resistance and dielectric strength.

Cost And Process Complexity

If the same specification IP67 is upgraded to IP68, the unit price of sealant and high-precision mold in the BOM will increase by 15-20%; in addition, a 96-hour salt spray and vibration temperature cycle composite test is required, and the vacuum leak detection cycle before each batch is shipped is extended from 1 min to 3 min. For non-continuous immersion applications, this part of the premium is often difficult to recover. Therefore, if there is no need for long-term underwater work, there is no need to blindly pursue IP68-level micro switches.

Typical Applications Of IP67 Waterproof Micro Switches

IP67 waterproof micro switches are currently most widely used in automotive scenarios, and IP67 has covered more than 90% of external switch requirements. Here are a few waterproof micro switches that are most widely used in automobiles.

Automobile Door Lock Switch

Automotive door lock modules need to maintain long-term stable operation in rain, dust and melting snow. The micro switch integrated in the lock body must ensure accurate feedback in the case of moisture or short-term immersion in water. IP67 waterproof micro switches are completely dustproof and waterproof for 30 minutes at a depth of 1 meter, and are suitable for reliable position signal acquisition in such enclosed spaces. Recommended reading: [Automobile door lock micro switch solution]

Car Seat Adjustment System

The electric seat adjustment mechanism is in a high-frequency action and high-humidity bottom environment for a long time. The waterproof car seat adjustment switch can effectively prevent dust and water vapor from entering the internal contacts, ensuring the reliability of the adjustment position feedback. It is suitable for key control nodes such as multi-directional adjustment limit and memory function triggering.

Seat Belt Reminder System

The detection structure inside the seat belt socket needs to ensure signal consistency under the intrusion of dust, sweat and cleaning water. The IP67 seat belt reminder switch provides stable contact and anti-interference performance to ensure that the reminder is triggered when the seat belt is not inserted, avoiding false alarms or signal failure. Its compact structure is suitable for seat pre-embedded design.

If you want to apply the waterproof micro switch to the car, it is recommended to browse the Unionwell automotive micro switch page, which collects all waterproof micro switches for automotive applications, all of which meet the IP67 protection level. Support customer customization of action force, lead wire, and mounting hole position to help OEMs and Tier1 accelerate mass production and delivery.

Typical Applications Of IP68 Waterproof Micro Switches

Ship Deck And Engine Room Control Systems

Ship equipment is exposed to sea fog, salt crystals and strong wind and wave impacts all year round, which places extremely high demands on the sealing and corrosion resistance of micro switches. IP68-rated switches can be immersed in salt water environments for a long time, have a fully sealed structure, and support deep-water operations and high-pressure washing. Widely used in propeller angle detection, engine room control panels and outboard engine start circuits to ensure reliable response under harsh sea conditions.

Deep-Sea Equipment: Rov And Underwater Lighting Systems

Remotely operated vehicles (ROVs), underwater robots, photography lights and other equipment work in static pressure environments of 2–3 meters or even deeper, and need to maintain stable electrical connections for a long time. IP68 waterproof micro switches are designed with customized potting, pressure equalization and water pressure-resistant structures to ensure that they can still operate correctly after continuous immersion in water for more than 72 hours. They are the preferred trigger components for underwater long-term deployment systems.

Outdoor Energy Storage Cabinets And High-Voltage Charging Piles

Outdoor energy storage systems and new energy charging terminals generally require regular cleaning with high-pressure water guns, with water pressures as high as 8–10 bar. Traditional IP67 switches are difficult to resist such impacts. The upgraded IP68 micro switch uses a 304 stainless steel metal handle, double-layer potting and pressure-resistant seals, and can operate more than 100,000 times at twice the pressure of the IEC standard. It is widely used for control cabin locking, door feedback and status signal detection.

How To Test The Waterproof Level?

Verification method specified by IEC 60529

IP67 and IP68 both use the static water immersion method. The sample is powered on or 1.1 times the rated voltage is applied, and the time is counted after immersion to the specified depth. The insulation resistance and operating characteristics are tested immediately after leaving the groove, and must not be less than 90% of the factory value. The factory can also entrust a third-party laboratory (TÜV, UL, SGS) to issue a report, and buyers can verify the authenticity on the official website through the report number.

Unionwell's IP67 Factory Test Process

In order to ensure that every waterproof micro switch can operate stably at the customer's site, Unionwell has established a rigorous factory test process. All products with IP67 grade requirements must pass the real underwater power-on test after potting: we will put the sample into 15 cm deep water for 30 minutes to simulate the short-term immersion or flushing environment in the actual application scenario. During the whole process, the switch must remain sensitive and free of electrical faults.

For customers with higher environmental requirements, we support entrusting professional institutions to conduct tests, and can issue third-party verification reports from authoritative testing institutions. The whole process is traceable to ensure worry-free delivery quality.

FAQ About IP67 Waterproof Micro Switch

Can IP67 Switch Directly Replace Indoor IP40 Products?

Yes, but it is necessary to confirm that the rated current, wiring terminals and installation holes are consistent, otherwise it may cause contact temperature rise or assembly interference.

Can IP67 Switch Withstand High-Temperature Steam Cleaning?

The IP67 protection level does not cover the test requirements for high-temperature steam cleaning. This type of cleaning not only has high temperature, but also high-pressure shock and alternating expansion of cold and hot, which exceeds the setting scope of the IP67 standard.

Why Are The Quotations Of Some Products With The Same IP67 Twice As Much?

The differences mainly come from the sealant grade, metal sheet material (brass vs silver-plated alloy) and batch reliability sampling items. Check the third-party report and life curve to distinguish.

Does The IP67 Micro Switch Require a Special Harness Seal?

If the switch body reaches IP67, but the harness and housing interface are not waterproofed with glue, the entire system may still fail. It is recommended to use pre-injected wire harnesses or heat shrink tubing.

Can The Existing Product Be Upgraded To IP68 By Adding Potting Technology?

It is theoretically feasible, but the terminal lead-out and exhaust holes need to be redesigned, and safety certification needs to be re-performed. At this time, the technical requirements and costs are higher.

Conclusion

Whether to choose IP67 or IP68 is essentially a balance between risk and cost: if your device only works in rain or short-term immersion, IP67 can meet the ten-year maintenance-free requirement; if it must be immersed for a long time or withstand high-pressure washing, it should be locked in place at one time to avoid brand and economic losses caused by later repairs.

Relying on 30 years of sealing technology accumulation, Unionwell can provide automotive and new energy customers with a full range of IP40-IP67 dustproof micro switches and waterproof micro switches, and support third-party reports and exclusive environmental simulation tests. If you are looking for a waterproof micro switch that meets IP67, please contact Unionwell to receive a free sample test!