ATEX & IECEx Intrinsically Safe IoT Design

Next-Generation Intrinsically Safe IoT Design for Hazardous Areas

Designing electronics for hazardous areas requires careful control of energy, temperature and fault conditions. We specialise in intrinsically safe IoT devices, low power sensing and wireless communication, supporting you from protection concept selection through to certification and manufacturing.

Book your intrinsically safe design consultation

Speak to us about your hazardous area product or technical challenge. Our engineers will help define your initial requirements, review suitable protection concepts, and outline the most practical route to a compliant, manufacturable solution.

  • Early-stage guidance on intrinsic safety and protection concept selection
  • Feasibility input on power, sensing and wireless system design
  • Clear next steps towards certification and manufacturing

Book your free consultation to assess your requirements and move your project forward with confidence.

Book a free consultation

Talk to our intrinsically safe design engineers today – book your free consultation.


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    Intrinsically safe IoT design from concept to production

     

    We design and develop intrinsically safe connected IoT devices for hazardous areas, combining low power sensing, wireless communication and compliance expertise. From early-stage requirements and protection concept selection through to certification and manufacturing, we provide a clear, structured path to a compliant, production-ready product.

    Intrinsically safe

    Intrinsically Safe Device Design

    Energy-limited electronics designed for safe operation in hazardous areas.

    Wireless

    Next-Generation IoT & Wireless
    Designed with BLE, Wi-Fi, LoRa, NFC and modern low power communication technologies.

    Compliance & Certification

    Structured support to achieve ATEX and IECEx approval with confidence.

    Manufacturing Support

    Design for manufacture and production support from prototype to scale.

    Intrinsically Safe IoT Design Intrinsically Safe IIoT Systems Hazardous Area IoT Devices Zone 0, 1 & 2 Devices Low Power IoT Ultra Low Power Sensing Wireless Sensor Networks Battery Powered IoT Devices Industrial IoT Connectivity BLE Device Design Wi-Fi IoT Systems LoRa & LPWAN Devices NFC & Short-Range Communication Edge IoT for Hazardous Areas Connected Sensor Systems Embedded IoT Electronics ATEX & IECEx IoT Design Intrinsic Safety for Wireless Devices Protection Concept Selection Intrinsic Safety Calculations Certification Support ATEX & IECEx Certification Test House Coordination Design for Certification Manufacturing Support

    Intrinsically safe IoT, engineered for the next generation of hazardous area products

    Most hazardous area equipment wasn’t designed for connectivity, low power operation, or modern data-driven use cases. We help bridge that gap, turning concepts and legacy systems into next-generation, intrinsically safe IoT devices built for real-world deployment.

    Our focus is on ultra low power sensing and modern wireless communication, enabling reliable data capture in environments where safety, battery life and robustness are critical. Whether you’re developing a new product or upgrading an existing design, we define the right architecture and protection approach from the outset.

    We support the full journey from concept through to ATEX and IECEx certification and production, ensuring your product is not only compliant, but engineered to perform in demanding industrial environments.

    We typically help clients to:

    • Turn concepts into intrinsically safe IoT devices for Zone 0, 1 and 2

    • Upgrade existing equipment with low power sensing and wireless connectivity

    • Design battery-powered systems for long-term deployment in the field

    • Integrate BLE, Wi-Fi, LoRa, NFC and emerging technologies

    • Develop products that are ready for certification, manufacture and scale

    What our clients say

    • The call was informative, understanding and thought provoking.We worked together to understand my project. I look forward to us working together.

      MD Harper Avatar MD Harper
      8th April 2026

      Prompt and punctual online meeting with a well briefed knowledgeable listener, what more could wanted?

      peter Avatar peter
      17th December 2025

      Great service in designing, prototyping and initial manufacture of a few units of a small electromechanical unit. The project was delivered on time and Ignitec were able to provide... read more

      Barney Eley Avatar Barney Eley
      17th December 2025
    • Quick response. Very informative first meeting. Very interested to continue with you

      Kamal Okasha Avatar Kamal Okasha
      10th December 2025

      Outstanding service — highly professional, incredibly responsive, and consistently flexible in adapting to the needs.

      Davis Yeung Avatar Davis Yeung
      13th November 2025

      Outstanding service — highly professional, incredibly responsive, and consistently flexible in adapting to the needs.

      A Google User Avatar A Google User
      13th November 2025
    • Highly recommend! Great work, professional, and friendly.

      Matt Jackson Avatar Matt Jackson
      23rd October 2025

      Ignitec assisted us in taking a prototype through the design phase to manufacturing. Their expertise in electrical design was evident, and the communication through collaborative tools was excellent, effectively bringing... read more

      Alex Tweed Avatar Alex Tweed
      10th October 2025

      I would like to express my sincere gratitude to the team at Ignitec for the invaluable support they have provided—not only to me personally but also to the Somerset Sight... read more

      Tim Cullen Avatar Tim Cullen
      11th September 2025
    • So we have been more than happy with James’s work. There was not a question that he couldn’t answer. a very experienced man worth every penny. I would definitely Recommend... read more

      Elliott Spokes Avatar Elliott Spokes
      29th August 2025

      Thank you James and Ignitec for the great work on our project! Communication and planning was brilliant to name a few of the great aspects working with you! Will definitely be... read more

      Kadir Acik Avatar Kadir Acik
      28th August 2025

      Very professional and friendly consultation

      Bh 11 Avatar Bh 11
      24th July 2025
    • ⭐️⭐️⭐️⭐️⭐️ We worked with this product design company to to help take our project to the next level, and the experience was exceptional from start to finish. They truly understood our... read more

      Darryl Samuel Avatar Darryl Samuel
      21st July 2025

      I've had the absolute pleasure of working with Ignitec in Bristol for both mechanical and electrical design and development, and I genuinely can't recommend them highly enough. From the outset,... read more

      simon Sixsmith Avatar simon Sixsmith
      9th July 2025

      An outstanding mechatronics consulting firm—proactive, provides excellent service, and is highly recommended.

      Law Samuel Avatar Law Samuel
      4th June 2025
    • Ignitec has consistently exceeded expectations with the services they've delivered. The quality of their work has been outstanding, and their communication throughout every stage of development has been exceptional. Their dedication... read more

      Marcus Parker Avatar Marcus Parker
      3rd June 2025

      Ignitec's friendly, professional team delivered our project on time despite a tight deadline and provided great support throughout. Highly recommended!

      L&Ts Avatar L&Ts
      8th May 2025

      Great people, excellent knowledge

      Ben Bright Avatar Ben Bright
      28th February 2025
    • James, Ben and everyone at Ignitec are great to work with. Super helpful, great communication, and a nice easy development process. Highly recommended!

      Ian Stevens Avatar Ian Stevens
      24th February 2025

      It has been a pleasure to work with Ignitec. The service has been professional and carried out to a very high standard. Communication has been great, and prototype hardware has... read more

      Kieran Tyrrell Avatar Kieran Tyrrell
      10th February 2025

      The engineers at Ignitec are outstanding. They truly grasp your requirements and work diligently alongside you to ensure you’re thrilled with the final outcome. I highly recommend Ignitec!

      Michael Stevens Avatar Michael Stevens
      18th December 2024
    • Ignitec have been an absolute joy to work with. They've exceeded our expectations every step of the way. We can't recommend them highly enough.

      Charles Wren Avatar Charles Wren
      17th December 2024

      James worked his ass off to get our project done

      Luke Cox Avatar Luke Cox
      26th September 2024

      Great engineers who understand your needs and work with you to make sure you’re happy with the end result, I would highly recommend Ignitec!

      N Y Avatar N Y
      3rd August 2024
    • It's been a great experience working with the product design teams at Ignitec over the last 9 years or so who are totally professional in everything they do. They come... read more

      Ian Fisher Avatar Ian Fisher
      18th July 2024

      Great team to work with. Real can-do attitude and lots of great suggestions. Thanks!

      Tom Marshall-Andrews Avatar Tom Marshall-Andrews
      28th February 2024

      Ignitec were great to work with - they helped us from concept through to the delivery of the project, with great attention to detail and weekly check-ins that kept us... read more

      Adam Stark Avatar Adam Stark
      16th February 2024
    • It's rare to find a company so driven to please its customers. Ignitec have bent over backwards to help us get our fledgling product off the ground. The project hasn't... read more

      Zeke Steer Avatar Zeke Steer
      3rd August 2023

      Ben and his team are just brilliant. In terms of quality, cost and every other important metric, Ignitec really deliver. Every encounter becomes a discussion with loads of good advice... read more

      UltraMarine Safety Avatar UltraMarine Safety
      17th May 2023

      I have worked with the Ignitec team for several years on many different projects and would highly recommend them to anyone in need of truly creative ideas and cutting edge... read more

      Christian Thorne Avatar Christian Thorne
      14th August 2022

    Book a free consultation

    Talk to our electronic design engineers today – book your free consultation

    Engineering the next generation of intrinsically safe IoT devices

    Most hazardous area systems were never designed for connectivity, low power operation, or modern data-driven use. Today’s environments demand more, with intelligent sensing, edge decision-making, and reliable wireless communication operating safely in Zone 0, Zone 1 and Zone 2.

    We design intrinsically safe devices that combine ultra low power sensing, embedded intelligence, and modern wireless technologies, enabling systems to not just collect data, but process it at the edge and act on it in real time. This reduces reliance on infrastructure, improves responsiveness, and unlocks new capabilities in environments where safety and reliability are critical.

    Whether developing new intrinsically safe products, upgrading existing equipment with low power sensing and wireless connectivity, or adapting non-intrinsically safe designs for use in hazardous areas, we define the right architecture, protection concept, and system design from the outset.

    This approach is particularly relevant in industries such as oil and gas, chemical processing, mining, food and grain handling, pharmaceutical manufacturing, and water and utilities, where hazardous environments and operational risk demand more capable, connected systems.

    By managing the full development process in-house, we ensure tight integration between electronics, firmware, wireless systems and compliance, reducing risk and accelerating your path to certification and production.

    Specialist knowledge

    Specialist Knowledge

    Expertise in intrinsically safe design, low power systems and wireless IoT.

    Integrated engineering

    Integrated Engineering

    Electronics, firmware and compliance developed together from the outset.

    Certification support

    Certification Support

    Hands-on with test houses and navigating ATEX and IECEx.

    Reduced risk

    Reduced Risk

    Early design decisions that minimise rework and certification delays.

    Explore our projects

     

    West technology forensics Forensic autorotator

    Controller for subsea exploration designed and delivered in low-volume batches on a fast turnaround.

    CASE STUDY | Marine, Subsea, Energy

    MESH GLOBAL

    DigitalMe

    Custom water level sensor for monitoring arctic glacial melt to support world-class research institution.

    CASE STUDY | Marine, Monitoring

    AARHUS UNIVERSITY

    DigitalMe

    Custom firmware for multi-mode NFC reader/writer supporting encrypted ticketing and tag emulation.

    CASE STUDY | IoT, Wireless

    SMART IMPACT

    Our design processes are fully ISO 9001 certified, ensuring consistency, traceability, and reliability at every stage of your project.

    Expert solutions for highly regulated industries

    Aerospace

    Hazardous locations

    Automotive

    Defence

    Medical

    Energy

    IoT

    Subsea

    Trusted by global leaders to deliver world-class design

    Book your Intrinsically Safe Design consultation with our team

    Talk to an expert about your Intrinsically Safe design requirements now. Our design team are ready to discuss your requirements, answer your questions and review your designs. Get free, expert advice via an introductory video call or an in-person meeting now.

    IMG 3362 (1)

    FAQ’s

    What is intrinsically safe design?

    Intrinsically safe design refers to creating products that can safely operate in hazardous environments without causing ignition. It focuses on reducing the energy available to the system to ensure explosions can’t occur.

    Why is intrinsically safe design important?

    It’s crucial for ensuring the safety of products used in potentially explosive atmospheres. Ensuring a product’s intrinsic safety can prevent accidents, safeguarding both the users and the environment.

    How do products achieve intrinsically safe design?

    Products achieve this by limiting the energy available within the system, ensuring it’s too low to ignite explosive gases or dust. This is done through design considerations and protective measures.

    When should intrinsically safe design be considered?

    It should be considered for any product intended to be used in an environment with a potential risk of gas, vapour, or dust explosions. Such environments can be found in industries like health tech, clean technology, and IoT.

    Who regulates intrinsically safe design standards?

    There are various international and national bodies that set standards and regulations for intrinsically safe designs. In the UK, one of the primary bodies is the Health and Safety Executive (HSE).

    Which industries require intrinsically safe designs the most?

    Industries operating in environments with a potential risk of explosions, such as the petrochemical, mining, pharmaceuticals, and agriculture sectors, heavily rely on intrinsically safe designs. These designs ensure that devices and systems within these sectors don’t ignite flammable gases, vapours, or dusts, thus prioritising safety and reducing the risk of catastrophic events.

    What are the benefits of intrinsically safe design?

    Ensuring intrinsic safety means products can be reliably used in hazardous environments without causing ignition. This reliability can save businesses from potential liabilities and protect users from harm.

    How is intrinsically safe design different from explosion-proof design?

    While both ensure safety in explosive environments, intrinsically safe design prevents explosions by limiting energy, while explosion-proof design contains and isolates any potential explosions within a robust enclosure.

    Why do some industries not use intrinsically safe designs?

    Not all environments pose a risk of explosion. Industries without such risks may not require the specific considerations of intrinsically safe design.

    Who can evaluate a product for intrinsically safe design?

    Specialised regulatory bodies and independent testing organisations can evaluate products for intrinsic safety. In the UK, this would typically be under guidelines set by the HSE.

    Which components are crucial in an intrinsically safe system?

    Important components include barriers to limit voltage and current, protective circuitry, and specialised materials that prevent spark or heat generation.

    When did intrinsically safe design principles originate?

    The principles have evolved over many years as industries recognised the need for safety in explosive environments. The formalisation of these principles into standards and guidelines has been a more recent development in the broader context of industrial safety.

    How do companies ensure ongoing intrinsically safe operation?

    Companies implement regular maintenance checks, periodic testing, and continuous training to ensure that the designed safety measures remain effective throughout the product’s lifecycle.

    What challenges are faced in intrinsically safe design?

    Challenges include staying updated with changing regulations, ensuring all components meet safety standards, and balancing functional requirements with safety considerations.

    Which tests are crucial for intrinsically safe design validation?

    Hazard analysis, risk assessment, environment testing, and compliance testing are vital to validate a product’s intrinsic safety.

    How are intrinsically safe devices marked?

    Devices that are certified as intrinsically safe usually bear specific markings or labels, indicating their compliance with the relevant standards and their suitability for specified hazardous environments.

    What are the consequences of not adhering to intrinsically safe design?

    Failure to adhere can lead to catastrophic accidents, financial liabilities, and legal consequences. Furthermore, it can jeopardise the safety of users and the environment.

    Why are there different intrinsically safe design standards?

    Different regions and industries have unique environmental and operational requirements. Therefore, standards are developed to address these specific needs, ensuring products are safe for their intended use.

    Who is responsible for ensuring a product's intrinsic safety?

    While design and manufacturing companies play a primary role, ensuring intrinsic safety is a collective responsibility, involving regulatory bodies, testing organisations, and end-users.

    What are the primary considerations in intrinsically safe design?

    Intrinsically safe design prioritises limiting electrical and thermal energy to ensure that devices cannot ignite a flammable atmosphere. This often involves the use of energy-limiting components, barriers, and safe separation distances

    How are components selected for intrinsically safe design?

    Components for intrinsically safe design are chosen based on their ability to operate safely within defined energy parameters. They should not produce sparks or get hot enough to cause ignition, and their specifications must match the defined safety parameters for the intended environment.

    Which standards guide intrinsically safe design requirements?

    Intrinsically safe design requirements are often guided by international standards such as IEC 60079 and regional standards like ATEX in Europe. These standards provide detailed guidelines on designing equipment for explosive atmospheres.

    Why are energy-limiting devices crucial in intrinsically safe design?

    Energy-limiting devices are essential because they restrict the electrical energy in a circuit, ensuring it remains below the level that can ignite a particular gas or dust. This ensures that even in the event of a fault condition, the environment remains safe.

    When designing for intrinsically safe environments, what considerations are given to potential fault conditions?

    In intrinsically safe design, consideration for potential fault conditions is paramount. The design must ensure that even in the event of faults like short circuits or component failures, the electrical and thermal energy remains below ignition-capable levels for the specific hazardous environment.