Can die cast housings meet IP65 or higher ingress protection standards?
Can Die Cast Housings Meet IP65 or Higher Ingress Protection Standards?
Understanding IP Ratings for Die Cast Housings
Ingress Protection (IP) ratings define the level of sealing a component offers against dust and moisture. An IP65 rating signifies complete protection against dust and low-pressure water jets, while IP66, IP67, or IP68 involve higher levels of resistance, including heavy spray or immersion. For aluminum die cast housings used in outdoor electronics, marine lighting, industrial control boxes, or automotive electronics, meeting IP65+ standards is both achievable and common when proper design and sealing are applied.
How Die Casting Supports IP-Rated Enclosures
Die casting enables the creation of complex, seamless geometries that enhance protection from environmental exposure. Alloys such as A360, ADC12, and AlSi12 offer the required dimensional stability and corrosion resistance to maintain tight seals over extended service periods.
Die casting advantages for IP-rated parts include:
High-precision sealing grooves and gasket channels
Uniform wall thickness for structural rigidity
Integrated mounting bosses to reduce secondary penetrations
Consistent surface finish for effective gasket compression
Key Elements for Achieving IP65 and Higher Ratings
Tool and Die Accuracy: Precision tool and die making ensures smooth gasket seating and dimensional repeatability.
Post-Machining of Sealing Surfaces: CNC machining ensures flatness and surface quality at the gasket interface for consistent IP performance.
Gasket Selection and Compression Design: Silicone, EPDM, or foam gaskets must be matched to groove design, bolt torque, and cover stiffness to prevent leaks.
Coatings and Finishes: Surface finishes such as anodizing or powder coating resist corrosion, ensuring the integrity of the sealing surfaces over time.
Assembly and Validation: Assembling processes should apply even torque across fastening points. Neway can conduct IP testing and leak validation to confirm target protection levels.
Typical Applications of IP-Rated Die Cast Housings
Outdoor LED lighting enclosures
Marine or dockside electronic control boxes
EV charging ports and power modules
Industrial instrumentation housings in dusty or humid zones
Neway’s End-to-End IP-Rated Housing Solutions
Neway delivers die cast housings capable of meeting IP65 and higher standards through:
Sealing-optimized aluminum die casting
Protective coatings and corrosion resistance finishing
Complete assembly and inspection services including IP testing protocols
