Designing Electronic Boards for Harsh Environments: Protection and Performance

The design of electronic boards is heavily influenced by the physical, climatic, and chemical conditions of the environments where devices operate. In harsh settings, the integrity and efficiency of the boards can be compromised by critical factors such as humidity, extreme temperatures, corrosive gases, and dust. Ensuring reliable and durable performance requires advanced technical solutions and meticulous design.

Extreme Temperatures

Electronic boards used in environments with particularly high or low temperatures require specific designs to manage material expansion and contraction, which can cause micro-cracks, component damage, and solder joint failures. High temperatures accelerate the degradation of insulators, while very low temperatures impair the performance of capacitors and other sensitive components.

Humidity and Contamination

Humidity is a leading cause of electronic failures, especially in outdoor, industrial, or marine environments. Water and vapor induce oxidation, corrosion of metallic components, and short circuits, while conductive dust, such as metallic or carbonaceous particles, can create unwanted electrical paths or cover sensors, reducing accuracy. Corrosive gases and chemicals can react with solder metals, degrading copper traces and weakening component joints.

Vibrations and Impacts

In industrial, automotive, or aerospace applications, electronic devices exposed to constant oscillations, intense vibrations, or sudden impacts face both mechanical and functional challenges. Without proper protection, these mechanical stresses can damage solder joints, loosen contacts, break traces, or affect the operation of sensitive components like sensors or microprocessors.

Electromagnetic Compatibility (EMC)

In environments with strong electromagnetic fields, such as hospitals or industrial facilities, electronic boards are subject to significant interference that can disrupt operations, causing system crashes, unexpected resets, or data transmission errors. Devices intended for such conditions must be designed to withstand electromagnetic disturbances and prevent malfunctions through careful signal management, component shielding, and designs that minimize electromagnetic emissions.

Enhancing Thermal, Chemical, and Humidity Resistance

To design electronic boards capable of operating under extreme conditions, selecting materials like high-performance laminates is crucial for superior thermal and chemical resistance.
Protective coatings, such as conformal coating, create a thin protective barrier, while potting involves embedding the board in protective resins, providing airtight sealing against external agents. Effective thermal management solutions, including heat sinks, fans, and printed circuit boards with extended ground planes, support cooling, while using components with broad thermal tolerances ensures operational continuity even amid temperature fluctuations.

Robust Mechanical Design and Electromagnetic Shielding

In environments characterized by vibrations and impacts, the electronic board layout should be revised to distribute mechanical stresses more evenly. Support brackets, vibration-absorbing materials, and robust mounting techniques help prevent mechanical failures.
In contexts with intense electromagnetic fields, such as industrial plants or medical environments, integrating shielding and filters on critical circuits is essential to reduce external interference and improve electromagnetic compatibility. A well-optimized ground plane layout, combined with precise high-frequency trace management, minimizes unwanted emissions and ensures proper device functionality.

Electronic Board Design for Harsh Environments with Syen

Syen is an expert partner supporting companies in creating electronic boards for harsh environments, offering customized solutions tailored to the specific needs of each project. With advanced engineering expertise, deep material knowledge, and meticulous attention to detail, Syen’s design and development team provides guidance and support at every stage, from material selection to final validation. With Syen, you can tackle the most complex challenges, ensuring safety and reliability even in the toughest conditions.

Discover our bespoke design services