Potting for Industrial Sensors
Precision cavity potting for industrial proximity, pressure, temperature and level sensors — achieving IP67–IP69K protection against washdown, chemical and vibration exposure.
High-Reliability Potting for Harsh-Environment Industrial Sensors
Industrial sensors — inductive and capacitive proximity switches, pressure transmitters, temperature probes and level sensors — are installed directly on production machinery, tanks and process equipment where they routinely face washdown cleaning, chemical splash, coolant exposure, sustained vibration and wide ambient temperature swings. Potting the sensor housing cavity with a two-component resin protects the internal electronics and wiring connections while preserving the accuracy of the sensing element itself, achieving the IP67 to IP69K ingress ratings that harsh industrial environments demand.
The dispensing challenge is filling the sensor cavity completely around often compact internal electronics without introducing air voids, while precisely avoiding the active sensing face or element — whether that's an inductive coil, a pressure diaphragm or a temperature-sensing junction — where potting material intrusion would degrade or eliminate sensor function entirely. Cable entry and strain relief at the connector or cable gland location require equally careful attention, since this transition point is a common failure location for field-installed sensors subject to cable movement and vibration.
SANCO precision cavity dispensing systems, built on our desktop visual dispensing machine platform, deliver the sensing-element keep-out precision, mix-ratio accuracy and vacuum degassing integration required for industrial sensor potting production across the full range of proximity, pressure, temperature and level sensing device types.
Why Industrial Sensor Potting Requires Harsh-Environment Reliability
Sensors mounted directly on production machinery face washdown, chemical and vibration exposure that potting must withstand while preserving sensing accuracy.
Sensing Element Keep-Out Precision
Potting compound must completely avoid the active sensing face — inductive coil, pressure diaphragm or temperature junction — since any material intrusion onto or into the sensing element degrades or eliminates sensor accuracy and function.
IP67–IP69K Washdown Resistance
Sensors installed in food/beverage, pharmaceutical and other washdown-cleaned facilities require IP69K-rated protection against high-pressure, high-temperature washdown spray; the potted seal must be complete and void-free to achieve this rating.
Cable Entry Strain Relief and Sealing
The cable or connector entry point is a common sensor failure location; potting must form a complete moisture seal around the cable jacket while providing mechanical strain relief against cable movement and vibration during field installation.
Chemical Resistance to Process Fluids
Sensors installed near process piping or tanks may face incidental exposure to process chemicals, cleaning agents or coolants; potting compound must resist degradation from these industrial chemical exposures over the sensor's service life.
Vibration Resistance for Machine-Mounted Sensors
Sensors mounted directly on production machinery experience sustained operational vibration; the potted assembly must maintain both mechanical integrity and sensing accuracy under this continuous vibration exposure.
Compact Cavity Volume with Complete Coverage
Industrial sensors are often compact, particularly proximity and level sensors in standardized housing sizes, requiring precise low-volume potting that still achieves complete coverage around internal electronics within a constrained cavity.
Key Capabilities for Industrial Sensor Potting
Sensing Element Keep-Out Dispensing
Programmable dispensing paths precisely avoid active sensing faces and elements, ensuring potting material never compromises sensor accuracy or function.
Precision 2K Mix Ratio Control
Inline mixing meters resin and hardener at precise ratio immediately before dispensing, ensuring consistent cure properties throughout the potted cavity.
IP69K-Grade Void-Free Fill
Vacuum degassing integration and controlled dispensing achieve the void-free, complete cavity fill required for high-pressure washdown-rated sensor housings.
Cable Entry Strain Relief Potting
Dispensing process forms a complete moisture seal and mechanical strain relief around cable or connector entry points.
Chemical-Resistant Compound Compatible
Dispensing system handles potting formulations engineered to resist process chemical, coolant and cleaning agent exposure.
Vibration-Resistant Formulation Support
Platform supports low-modulus, vibration-absorbing potting compounds suited to machine-mounted sensor applications.
Compact Cavity Precision Dosing
Low-volume precision dosing achieves complete coverage within the constrained cavity volumes typical of standardized industrial sensor housing sizes.
Inline Sensor Assembly Line Integration
SMEMA-compatible conveyor integration links SANCO potting equipment directly into sensor assembly lines between housing sealing and final calibration/test stations.
The Industrial Sensor Potting Process Step by Step
Sensor potting must achieve complete cavity coverage while precisely preserving sensing element function. SANCO equipment is calibrated for every stage.
Sensor Housing Load & Component Inspection
Assembled sensor housing is loaded and inspected for correct component placement and wiring before potting begins.
Two-Component Mixing & Metering
Resin and hardener are metered at specified ratio and mixed inline immediately before dispensing.
Cavity Fill Dispensing
Housing cavity is filled to target volume, following a programmed path that avoids the sensing element and connector.
Vacuum Degas / Bubble Release
Filled housing undergoes degassing to release entrapped air before the compound gels.
Cure & IP Rating Verification
Potting compound cures per specification; sample units undergo IP-rating ingress testing.
Industrial Sensor Potting Material Types & SANCO Compatibility
SANCO dispensing machines handle the two-component potting compounds used across industrial proximity, pressure, temperature and level sensor encapsulation.
| Material Type | Viscosity Range | Cure Method | Typical Application | SANCO Compatibility |
|---|---|---|---|---|
| General-Purpose 2K Epoxy Potting Compound | 5,000 – 30,000 mPa·s | Thermal 60–80°C or ambient | Standard potting for proximity switches and general industrial sensor housings | Recommended |
| Chemical-Resistant Polyurethane Potting Compound | 3,000 – 20,000 mPa·s | Ambient or thermal 40–60°C | Enhanced resistance to process chemicals and cleaning agents for sensors near tanks or piping | Recommended |
| Vibration-Absorbing Silicone Gel | 3,000 – 20,000 mPa·s | Thermal 60–100°C | Low-stress potting for sensors mounted directly on vibrating production machinery | Recommended |
| Washdown-Grade High-Adhesion Epoxy | 8,000 – 40,000 mPa·s | Thermal 60–80°C | IP69K-rated potting for sensors in food/beverage and pharmaceutical washdown environments | Recommended |
| Low-Viscosity Fast-Flow Epoxy | 1,000 – 8,000 mPa·s | Thermal 60–80°C or ambient | Complete-fill potting for compact sensor cavities with tight internal clearances | Recommended |
Frequently Asked Questions
How does SANCO avoid potting material contacting the active sensing element?
Programmable dispensing paths are precisely configured to avoid the active sensing face — whether an inductive coil, pressure diaphragm or temperature junction — ensuring complete surrounding coverage without ever compromising sensor accuracy. Contact our application engineers to review keep-out requirements for your sensor design.
What IP rating can industrial sensors potted with SANCO equipment achieve?
Achievable IP rating depends on housing design and material selection, but SANCO's void-free, precisely metered fill supports sensor housings rated up to IP69K when paired with an appropriate washdown-grade potting compound and complete cavity coverage.
Does SANCO provide strain relief sealing at the sensor cable entry point?
Yes. SANCO's dispensing process forms a complete moisture seal around the cable jacket at the entry point while providing mechanical strain relief against cable movement and vibration during field installation.
Can SANCO equipment pot sensors with very compact housing cavities?
Yes. Low-volume precision dosing capability achieves complete coverage within the constrained cavity volumes typical of standardized industrial proximity and level sensor housing sizes.
Does SANCO support chemical-resistant potting for sensors near process fluids?
Yes. SANCO dispensing systems handle chemical-resistant polyurethane and epoxy formulations engineered to resist degradation from process chemicals, coolants and cleaning agents common in industrial environments.
Where can I learn about other industrial electronics dispensing applications?
Visit our Applications section for guides covering conformal coating for industrial control boards, sealing for industrial connectors and potting for relays/transformers. For equipment specifications, see our dispensing machine product pages.
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