Waterproof AC/DC Power Adapter Full Custom Development Case Study | From Enclosure to Circuit Design

Full custom development case study of a waterproof waterproof AC/DC Power Adapter. We develop power supplies tailored to customer-specific requirements, providing comprehensive support from enclosure structure and circuit design to waterproof testing.

What Does "Full Custom" Mean for Waterproof AC/DC Power Adapter?

A fully customized waterproof AC/DC Power Adapter is a custom power supply developed from scratch, with its circuitry, enclosure, and waterproof structure designed to suit the customer's equipment and installation environment.

Our standard waterproof AC/DC Power Adapter are available in two series: 36W and 70W models rated IP65/IP67. Available output voltages are 12V, 15V, 19V, and 24V. For output specifications, shapes, or operating environments that cannot be accommodated by standard products, we offer semi-custom and fully custom solutions. To view our standard products, see "Waterproof AC/DC Power Adapter List."

For an explanation of how to interpret ratings such as IP65 and IP67, see "How to Choose a Waterproof AC/DC Power Adapter." This page introduces the items that can be designed through full customization and explains how to select the appropriate customization method.

How to Choose Between Standard, Semi-Custom, and Fully Custom Products

Even if you need a waterproof power supply, it does not necessarily have to be fully customized. We select the most suitable option from the following methods based on your requirements.

Differences Between Semi-Custom and Full-Custom

Depending on your requirements, a semi-custom solution may often be sufficient instead of a full-custom design. To avoid overengineering, we can assist you from the initial stage of defining and organizing your specifications. You are welcome to start by simply checking whether a semi-custom solution can meet your needs. Click here for semi-custom waterproof AC/DC Power Adapter >

Key Items in a Fully Customized Design

For a fully customized waterproof AC/DC Power Adapter, we primarily design the following six items to suit the customer's equipment and installation environment.

1. Waterproof Structure: Enclosure, Cable Outlets, and Connector Interfaces

Waterproof performance is not determined by the enclosure alone. We design the cable outlet seals and connector interfaces as well. We first determine whether the required rating must be met by the adapter itself or with the connector attached.

2. Thermal Design for a Sealed Enclosure

Because a waterproof structure requires a sealed enclosure, heat cannot easily dissipate. We design the adapter to provide the required output even at the highest temperature of the installation environment. During the design stage, we implement circuit designs that minimize temperature rise and provide sufficient margins for component ratings (derating).

3. Waterproof Connectors and Cables on the DC Side

Waterproofing equipment requires both the adapter body and the DC-side connector to be waterproof. We offer a standard selection of waterproof connectors, including those manufactured by Hirose Electric. We support more than 300 types of DC plugs and connection terminals, as well as custom cable lengths and the crimping of special terminals. You can consult us about both the power supply and connectors as a complete package.

4. Mounting Method

We design the mounting method to suit the equipment and installation location, such as fastening it to a wall with screws or securing it with brackets. During the design stage, we also check whether the equipment can be installed in an orientation that prevents water from running toward the cable outlet.

5. Measures Against Condensation, Humidity, and Salt Damage

IP ratings indicate the level of protection against the ingress of water and dust. Resistance to condensation, high humidity, and salt damage must be considered separately from the IP rating. Our factory is equipped to apply moisture-resistant coatings to circuit boards. Our quality verification tests include condensation testing, humidity testing, and salt spray testing (see "Reliability Testing" and "Thorough Products Design and Quality Verification").

6. Additional Outdoor Requirements: Operating Temperature Range, Lightning Surges, and Safety Standards

In addition to waterproofing, equipment used outdoors may require a wide operating temperature range and protection against lightning surges. We have developed a solution that combines waterproofing with operation from -20 to +60°C (see "Case Study: Waterproofing and Wide-Temperature Support"). We have also developed a solution for outdoor communications equipment that provides 20 times the lightning surge resistance of standard products (see "Case Study: Lightning Surge Protection"). These measures are also designed in combination with waterproofing.

The required safety standards depend on the type of equipment and the countries or regions where it will be sold. For details, see "Approach to Safety Standards."

Development Process and Waterproofing Evaluation

Our fully customized development process proceeds as follows.

1. Consultation on the operating environment and requirements
2. Conceptual design of the circuitry and enclosure
3. Prototyping and evaluation (including waterproofing evaluation)
4. Mass-production design and production launch

Evaluation is conducted based on the expected installation environment. From the initial design stage, we develop products with mass-production stability in mind.

For details on the eight-step process, see "Fully Customized Development Workflow."

Information to Provide When Contacting Us

• Required waterproof and dustproof rating and the conditions under which the rating must be met (the adapter alone or with the connector attached)
• Output voltage and current
• Temperature range at the installation location and conditions such as condensation and salt damage
• DC connector type and cable length
• Mounting method
• Countries and regions where the product will be sold (this determines the required safety standards)
• Number of prototype samples required and desired delivery date
• Planned start date for mass production and estimated annual quantity

You are welcome to contact us even if some details have not yet been finalized. We can assist you starting from the prototype sample stage. We will provide information on minimum order quantities and mass-production terms along with our quotation.

Customer Testimonials

We received the following feedback from a customer who requested a waterproof AC/DC Power Adapter for use around water as a custom power supply.

"We were having trouble finding an AC/DC Power Adapter for use around water. We also could not find a company that could provide a custom solution. When we contacted UNIFIVE, the process went very smoothly, which was extremely helpful." - Representative

Power Supply Cases for Equipment Used Outdoors and Near Water

Here are three other cases in which we provided power supply solutions for equipment used outdoors and near water.

Waterproof x Wide-Temperature-Range AC/DC Power Adapter (FA Equipment, Semi-Custom)

Standard products could not simultaneously meet the requirements for IP-rated waterproofing and operation from -20 to +60°C. Based on an existing 24 V product, we designed a waterproof enclosure using a new mold. We replaced some components with wide-temperature-range alternatives to maintain the rated output even at temperatures from -20 to +60°C. The customer began mass production as scheduled without changing the equipment design.

View the Waterproof x Wide-Temperature-Range Case Study >

Custom Power Supply with Enhanced Lightning Surge Resistance (Outdoor Communications Equipment, Fully Custom)

For communications equipment installed outdoors, damage caused by lightning surges was a major concern. By incorporating surge absorbers and reinforced insulation, we achieved 20 times the surge resistance of standard products. During field testing, there were no equipment failures caused by lightning strikes.

View the Lightning Surge Protection Case Study ▶

Board-Level Power Supply Integrated into an Outdoor Enclosure (POS Terminal, Fully Custom)

The device is integrated into an enclosure installed outdoors, with the power supply mounted inside the enclosure. Waterproofing and dustproofing are provided by the enclosure, while the power supply was supplied as a standalone circuit board. During the design stage, we selected the components and determined the heat dissipation paths to ensure that applying a moisture-proof coating to the board would not cause any issues. The thermal design enables fanless operation.

View the Custom Board-Level Power Supply Development Case Study for POS Terminals ▶

For more examples, please see "Custom Power Supply Case Studies."

Frequently Asked Questions

Q. How long does fully custom development take, and what are the initial costs?

A. It depends on the specifications. Fully custom development involves development, tooling, and safety certification costs. If a semi-custom solution is feasible, the development time and initial costs can be reduced. We will provide the schedule and costs along with your quotation.

Q. Is it possible to waterproof the equipment enclosure instead of the power supply itself?

A. Yes. A board-mounted power supply can be installed inside the equipment enclosure, with the enclosure providing waterproof and dustproof protection. If humidity or condensation is a concern, we can supply the board with a moisture-resistant coating.

Q. Can I consult with you about prototypes or small quantities?

A. Yes, we can assist you starting from the prototype sample stage. We will provide information about the minimum order quantity and mass-production requirements along with your quotation.

You can consult us about fully customizing a waterproof AC/DC Power Adapter even before the specifications are finalized.

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