Case study: sealing LED light fittings with EPDM rubber gaskets

Challenge: moisture ingress in luminaires

A European manufacturer of outdoor LED luminaires contacted us about a recurring problem: several series of streetlights installed in humid environments were suffering from internal condensation and premature electrical failures.

The customer's internal tests and after-sales reports confirmed that the failure was due to micro-ingress of water and dust through the existing sealing gasket, which did not provide a sufficient level of sealing for IP‑67 environments.

Solution: solid EPDM IP‑67 gaskets

Following a joint technical analysis, we proposed replacing the original gasket with a custom solution based on EPDM gaskets, designed to fit perfectly in the machined groove of the luminaire housing.

The reasons for selecting EPDM included:

• Excellent resistance to ozone, water, steam and UV radiation

• Strong performance outdoors and under variable temperatures

• Long-lasting sealing capacity even after expansion and contraction cycles

The proposed design improved the compression factor without deformation, ensuring a genuine and consistent IP‑67 degree of protection.

Results measured after 12 months

One year after implementing the change, the customer has seen:

• A 100 % reduction in moisture-related failures in the new series

• Lower replacement and after-sales costs

• Better perceived quality of the end product among distributors

The luminaires have successfully passed IP‑67 tests, even after accelerated ageing simulations (thermal changes and humidity cycles).

The customer's next steps

The customer has already requested that the redesign with EPDM gaskets be extended to other, larger product series, along with direct integration into the assembly process through custom kits supplied by Manufactures Cusell.

Need help choosing the right gasket for your next industrial project?
Contact us today at https://www.arandelasyjuntas.com to discuss your requirements and get expert advice. Manufactures Cusell is proud to offer a wide range of industrial gaskets designed to meet the highest standards of quality and environmental sustainability.