Environmental testing is a set of procedures that help verify how electronic devices perform under conditions similar to real-life ones. These tests make it possible to identify design weaknesses before the product reaches the market. They focus primarily on the effects of extreme temperatures, humidity and vibrations, which are among the most common causes of operational failures.
Why are environmental tests necessary?
Electronic equipment operates not in a laboratory, but in environments that can be demanding. In a car exposed to freezing temperatures, in a production hall at high heat, in a tropical climate, or in machines subject to vibrations. Skipping the testing of electronic devices can lead to field failures, repair costs, complaints, and loss of user trust. That is why environmental testing is treated as an investment in reliability.
What do environmental tests for electronics cover?
The scope of environmental testing most often includes resistance tests for: extreme temperatures (both high and low), cyclic temperature changes (thermal shocks), high humidity (including vapor condensation), and mechanical vibrations and shocks. Potential problems that can be revealed in controlled tests:
- Cracks in solder joints or components e.g., caused by thermal expansion of materials during repeated heating and cooling cycles.
- Corrosion or short circuits e.g., resulting from moisture condensation on the board or exposed connectors in high humidity conditions.
Loosened fasteners e.g., screws, connectors, or heavier components that may gradually loosen under continuous vibration.
Temperature testing in practice
Extreme temperatures, both too low and freezing, and too high and hot, can significantly affect the performance of electronic devices. Such conditions place a heavy load on the hardware. Temperature testing involves placing the device in a climate chamber and exposing it to extreme cold and heat for a defined period. The tests help determine whether the housing materials crack due to contraction and expansion, and whether the device continues to operate within its intended temperature range. Sudden temperature changes introduce mechanical stress. Components expand and contract at different rates, which can lead to cracked solder joints or microcracks in PCB traces. This kind of damage may result in unstable connections or complete system failure and can be detected during thermal shock testing. During this procedure, the device is first cooled to below 0 °C and then rapidly moved to a chamber heated above 130 °C. Another approach involves slower, cyclic temperature changes, for example in a single chamber where the temperature shifts at about 10 °C per minute between a defined minimum and maximum, simulating day and night cycles in a desert environment. Temperature testing also reveals components that cannot cope with certain extreme conditions. Detecting such weaknesses early enables changes to the design before the product enters mass production.
Moisture resistance tests
Moisture resistance tests show how a device copes with increased air humidity, and sometimes also with direct contact with water, such as rain or salt mist, if the product is intended for outdoor use. The tests are conducted in climate chambers that maintain high relative humidity and elevated temperatures to accelerate condensation. Under such conditions, water droplets or frost may form inside the enclosure, on printed circuit boards, or on optical components. This does not always cause immediate failure, but without proper protection, it may result in insulation cracks, peeling of material layers, or fogging of displays and lenses. Prolonged exposure to moisture introduces additional risks. Water droplets can cause short circuits, and high humidity promotes corrosion of metal parts. Unprotected copper tracks, connectors, or contacts may oxidize and rust, impairing conductivity or disabling the device entirely. Therefore, tests also assess the effectiveness of protective coatings, such as conformal coatings or anti-corrosion layers. If the manufacturer declares that the enclosure is waterproof, leak testing is included. The IP rating is verified to ensure that moisture does not enter the device.
Vibration and mechanical testing
Consumer electronics are also exposed to vibrations and mechanical shocks. Vibrations occur, among other things, in vehicles such as cars, trains or airplanes, during machine operation and even during equipment transport. Vibration tests involve subjecting devices to controlled vibrations of varying frequency and amplitude. The device is mounted on a special vibration table, called a shaker, which generates sinusoidal and random vibrations along all three axes. The purpose of these tests is to determine how resistant the structure is to shocks and whether any issues arise during vibration, such as power interruptions, signal loss, unwanted system resets or mechanical failures. After just a few dozen minutes of intense vibration, it is possible to detect components that begin to loosen, such as screws or connectors, as well as those that crack or detach due to material fatigue. This applies especially to larger and heavier components on the PCB and at soldered joints.Solder joints are susceptible to what is known as solder fatigue and to microcracks caused by cyclic mechanical stress. Sometimes, functional tests are conducted alongside vibration tests to ensure that vibrations do not interfere with the device’s operation, for instance by momentarily disconnecting board contacts. In addition to continuous vibrations, impact tests are used to simulate single shocks or drops. A typical impact test involves a sudden blow at a specific acceleration and is used to assess the device’s resistance to being dropped from a height. These tests may lead the manufacturer to implement design changes, such as reinforcing the housing, securing the PCB more firmly, or improving the protection of heavy components.
Environmental testing norms and standards
When performing environmental testing of electronic devices, there are established standards that describe standardized procedures and test scopes. These standards allow for the unification of testing methodologies and the requirements that equipment must meet in order to be recognized as resistant to specific factors. The most commonly used series is PN-EN 60068. Its individual parts define test methods for various factors, such as:
- PN-EN 60068-2-1 — resistance to cold,
- PN-EN 60068-2-2 — resistance to dry heat,
- PN-EN 60068-2-14 — cyclic temperature changes, including thermal shock,
- PN-EN 60068-2-30 — cyclic humidity,
- PN-EN 60068-2-38 — constant humidity.
Compliance with the requirements of such standards is sometimes necessary if a product is to obtain certification or meet the requirements of specific industries, such as automotive or aerospace. In practice, the standards applicable to a given device are determined at the test planning stage. The parameters of the environmental test loads are selected on that basis.
How to conduct environmental testing
Conducting reliable environmental testing requires appropriate laboratory facilities such as climate chambers or vibration tables. This equipment is expensive to purchase and maintain, and it also requires regular calibration. The testing process itself extends the project validation time. Test cycles must be planned, several prototypes intended for destruction must be prepared, and the tests themselves can last from several hours to many weeks. These include, for example, long-term corrosion resistance tests in a salt chamber or thermal aging tests. For these reasons, manufacturers may want to limit the testing scope in order to bring the product to market faster. However, this is a short-sighted approach. It is also unwise to go to the opposite extreme, but the tests necessary for a given device should be performed in full and with due diligence. In the longer term, this allows time and resources to be saved that would otherwise be spent on repairs and handling complaints. A robust device that meets requirements also improves brand image, attracts customers and can positively influence sales performance in the long run. Companies that do not have their own facilities can successfully use testing services provided by experienced external specialists. This gives them confidence that the testing of electronic devices has been carried out in accordance with applicable industry standards.
Test scope planning and product reliability
The most important thing is to properly match the scope and rigor of testing to the real operating conditions of the device. This requires experience and a good understanding of the environment in which the device will actually function. It is the engineers’ task to determine which limit values are meaningful and which would only act as artificial stressors. Tests that are too lenient may result in seemingly successful validation and, in consequence, failures in customer use. On the other hand, excessively strict testing extends the process and increases costs. It forces unnecessary reinforcement of components beyond their actual needs. There are also accelerated life testing methods, such as HALT and HASS, which go beyond standard use conditions to quickly reveal design weaknesses. Interpreting such results also requires expertise, since not every failure under extreme conditions translates into issues during day-to-day use. Each device needs an individual approach. There is no universal recipe for environmental testing. A good test plan is one tailored to the specific needs of a product by experienced engineers. If you would like to commission professional testing of electronic devices, contact us. At Device Prototype, we will help you select the right scope of testing and the parameters best suited for your project. Learn more about testing electronic devices ⬏.
