What is driving the increase in industrial wireless enclosure sizes?

Industrial wireless enclosure sizes are increasing because the wireless devices inside them are becoming larger, more capable and demanding more power.

The main drivers are:

• Wireless devices that require more internal space.
• More capable devices that need additional supporting components.
• Bigger power supplies to support increased power demand.
• Internal clearance requirements to ensure the device(s) fit correctly.
• Maintenance accessibility, including practical access to lids and components.

Together, these requirements mean the enclosure must be designed with enough internal capacity, clearance, and accessibility to support the hardware properly.

Designing Around the Demands of Modern Wireless Devices

Over the past 18 months, we have seen a significant increase in the size of the hazardous area wireless enclosures we are offering. That change is mainly being driven by the wireless devices themselves, but as enclosure requirements grow, wider design considerations become more important too.

It is not just a question of whether the wireless access point will fit inside the enclosure. The design must also consider where the enclosure will be installed, what conditions it will be exposed to, and how practical it will be to maintain over time.

For example, offshore locations such as Floating Production Storage and Offloading (FPSO) vessels, offshore rigs, and other demanding marine environments often require heavy duty enclosure designs, so material selection is part of that conversation. Stainless steel options, including Stainless Steel 316, can be relevant where corrosion resistance is needed, particularly where salt, humidity, and temperature changes are present. We cover this in more detail in our article on designing Ex wireless enclosures for high-salt environments.

Why the Access Point Drives the Enclosure Design

Access points are growing because they are capable of doing more. Increased capability often brings additional hardware requirements, which can make the device physically larger and more demanding to integrate.

Inside every enclosure, there is an internal envelope that the device(s) must fit into. There may be some flexibility in how hardware is positioned, and in some cases, it can be placed at an angle, but there is only so much adjustment possible within the physical limits of the enclosure. The hardware must still sit correctly inside the available space.

Making Space for Power and Cooling

As the access point is integrated into the enclosure, the supporting components also need to be carefully accommodated. We can look at how space is allocated around them, but when they are combined with a bigger access point, the enclosure itself often needs to become bigger too.

Clearance is also important because the enclosure has to support more than the physical footprint of the access point. There needs to be enough space for:

• Ventilation- allowing heat to escape from the enclosure or be managed properly. As access points, power supplies, and other components generate heat, the enclosure design needs to consider how that heat is controlled so the equipment can operate reliably.
• Air circulation– the movement of air inside the enclosure. Even if the enclosure has enough physical space, components should not be packed so tightly that air cannot move around them. Good air circulation helps prevent local hot spots around devices or power supplies.
• Bend radius- the minimum curve a cable or wire can safely make without being damaged or affecting performance. This is especially important for fibre cables, since bending them too tightly can affect signal quality or damage the cable. It also matters for general cable management because wires need enough space to be routed safely and practically.

The design also has to allow practical access for maintenance and inspection, so engineers can work inside the enclosure without components being too tightly packed together.

Designing for Maintenance, Not Just Installation

For Extronics (BARTEC’s Connectivity & IoT Brand), adapting enclosure design to meet changing market needs is a key part of how we support modern hazardous area wireless projects. The market is changing, and enclosure design has to move with it. It is not just about making a bigger box; it is about understanding what the hardware now requires and designing around that properly.

That also means carefully considering standard maintenance as part of the design. Function and fit matter, yet so does accessibility. We need to think about how accessible the lids are and how practical the enclosure is for the people who will install, inspect, and maintain it.

When Devices Do More, Enclosures Have to Adapt

As technology output increases, the endpoint is expected to do more. In some cases, that means one big box that does everything.

There is also a technology cycle to consider. When technology gets better, we may eventually see all-in-one devices that work differently and become smaller again. But often, devices get bigger first. They gain more capability, need more space, and then later, as chips and technology improve, they may reduce in size again.

This is why enclosure design must consider more than the access point itself. The aim is not just to house the hardware, but to support wireless connectivity safely and practically in hazardous areas where flammable gases and combustible dust are part of the operating environment. That means thinking about certification, installation, maintenance, and long-term use within the overall design.

To explore this in more detail, read our article: Design Principles Behind Hazardous Area Wireless Connectivity: iWAP107 and iWAPXN3 Explained.

Turning Engineering Knowledge into Guided Decisions

The Wireless Enclosure Configurator supports a more standardised and consistent approach to enclosure selection. Rather than treating each enclosure as a separate assessment, guided configuration helps apply engineering knowledge in a repeatable way.

This supports standardisation and rationalisation across the components and production processes involved. By making enclosure selection more structured, we can reduce unnecessary variation, improve consistency, and work towards more cost-optimised solutions for the customer.

As projects evolve, the configurator is continuously developed to reflect changing hardware requirements, enclosure considerations, and market needs. This helps keep the right technical checks in place while supporting clearer, more efficient decision-making.

For more information about this approach, read our article: Designed for Simplicity: How Rule-Based Automation Makes Hazardous Area Solutions Easier.

Keeping Pace with the Market

We are proud to respond quickly to market trends with practical engineering. Changes to the capabilities of wireless devices ultimately alter enclosure requirements. Our role is to stay adaptable, understand those changes, and apply them to enclosure design.

About the Author

ST

Simon Taylor

Configured Products Manager

Simon specializes in the testing, certification, and compliance of wireless enclosures, ensuring strategies that remain both innovative and Ex-safe. He has a deep passion for industry standards and isn’t afraid of a good compliance debate. Known for quickly identifying the critical path in complex projects, he brings clarity, confidence, and real value to his team and customers.

Last updated on June 10, 2026

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