Hi everyone,we need to enclose an esp32 project to be fully ip 67 and that a few of the sensors on board will be connected to it from outside in a way that would not compromise the rating,any suggestions?
Greetings,
Environmentally-tolerant cable penetrations through an enclosure wall are often managed by using a suitable cable gland or cord grip.. In more extreme cases, additionally filling the assembly with a suitable potting compound is also quite common.
If you want to make your ESP32 project fully IP67 while still connecting sensors from the outside, the main focus should be on the enclosure and cable entry points. A strong polycarbonate or glass-filled nylon box with a silicone gasket seal works best. Always use external mounting tabs so you don’t break the seal surface. For Wi-Fi or Bluetooth, prefer a plastic enclosure or use a sealed external antenna feedthrough.
For routing cables and connecting sensors, the most common solutions are IP68 cable glands or sealed bulkhead connectors. Cable glands are cheap and effective if you size them correctly to the cable diameter, while circular M8/M12 connectors give you a professional, serviceable option. For ultimate robustness, potted pigtails work well, where cables are permanently sealed through the enclosure. For sensors that must sense the environment (like humidity or barometric pressure), use a hydrophobic vent membrane to keep the enclosure sealed while letting the sensor “breathe.”
Another important detail is condensation and pressure changes. A sealed box heats and cools, which can draw in moisture. Adding a small IP67-rated vent plug helps equalize pressure and reduce condensation. Inside, you can also add a conformal coat on the PCB and use a desiccant pack. Strain relief on cables and drip loops outside the box will prevent water ingress over time.
For inspiration, you can check out this ESP32-CAM Host Board Project on PCBWay, which was designed to fit inside a waterproof housing. It demonstrates how to plan your PCB to fit neatly inside an enclosure and leaves room for adding batteries or sensors. This project shows how practical it is to design with waterproof enclosures in mind, and you can adapt a similar approach to your own IP67 ESP32 build.